U.S. patent application number 16/190920 was filed with the patent office on 2019-05-16 for light redirecting film constructions and methods of making them.
The applicant listed for this patent is 3M INNOVATIVE PROPERTIES COMPANY. Invention is credited to Erik A. Aho, Bing Hao, Manoj Nirmal, John F. Reed, Scott M. Tapio.
Application Number | 20190146126 16/190920 |
Document ID | / |
Family ID | 58873871 |
Filed Date | 2019-05-16 |
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United States Patent
Application |
20190146126 |
Kind Code |
A1 |
Nirmal; Manoj ; et
al. |
May 16, 2019 |
LIGHT REDIRECTING FILM CONSTRUCTIONS AND METHODS OF MAKING THEM
Abstract
The present disclosure relates to articles and methods of making
light redirecting film constructions comprising a microstructured
optical film, such as a daylight redirecting film, bonded to
another film. This type of assembly may serve various purposes. For
example, the assembly may protect the structured film, provide
additional functionality, such as diffusion or infrared reflection,
and/or facilitate attachment of the microstructured optical film to
a mounting surface, such as a glazing or window pane.
Inventors: |
Nirmal; Manoj; (St. Paul,
MN) ; Tapio; Scott M.; (Falcon Heights, MN) ;
Aho; Erik A.; (New Richmond, WI) ; Hao; Bing;
(Woodbury, MN) ; Reed; John F.; (North Oaks,
MN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
3M INNOVATIVE PROPERTIES COMPANY |
St. Paul |
MN |
US |
|
|
Family ID: |
58873871 |
Appl. No.: |
16/190920 |
Filed: |
May 12, 2017 |
PCT Filed: |
May 12, 2017 |
PCT NO: |
PCT/US2017/032360 |
371 Date: |
November 14, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62336726 |
May 15, 2016 |
|
|
|
Current U.S.
Class: |
359/599 |
Current CPC
Class: |
B32B 27/283 20130101;
B32B 27/34 20130101; B32B 7/04 20130101; B32B 7/06 20130101; B32B
3/30 20130101; B32B 2255/10 20130101; B32B 7/12 20130101; B32B
27/18 20130101; B32B 27/308 20130101; B32B 2307/748 20130101; B32B
27/22 20130101; B32B 2307/71 20130101; G02B 5/0278 20130101; B32B
23/00 20130101; B32B 27/08 20130101; G02B 5/0231 20130101; G02B
5/045 20130101; B32B 2605/006 20130101; B32B 27/20 20130101; B32B
27/304 20130101; B32B 27/365 20130101; B32B 27/40 20130101; B32B
27/00 20130101; B32B 2307/412 20130101; G02B 5/04 20130101; B32B
27/32 20130101; B32B 23/08 20130101; B32B 27/36 20130101 |
International
Class: |
G02B 5/02 20060101
G02B005/02; G02B 5/04 20060101 G02B005/04 |
Claims
1. A film construction comprising: a light redirecting film having
a first major surface and a second major surface opposite the first
major surface, wherein the first major surface of the light
redirecting film comprises a plurality of microstructured prismatic
elements, wherein one or more of the microstructured prismatic
elements have a first peak and a second peak, wherein the first
peak has a height H1 and the second peak has a height H2, wherein
H3 is H1-H2, and H3 is equal or greater than 1 micrometer, an
adhesive layer comprising an adhesive, wherein the adhesive layer
has a first major surface and a second major surface opposite the
first major surface, a cover film having a first major surface and
a second major surface opposite the first major surface, wherein
the first peak of one or more of the microstructured prismatic
elements penetrates at least partially into the first major surface
of the adhesive layer, wherein the second major surface of the
adhesive layer is adjacent to the first major surface of the cover
film.
2. The film construction of claim 1, wherein H3 is from 2
micrometers to 8 micrometers.
3. The film construction of claim 1, wherein the second major
surface of the adhesive layer is immediately adjacent to the first
major surface of the film.
4. The film construction of claim 1, wherein when the film
construction is in a vertical position, the first peak of the
microstructured prismatic element is positionally located above the
second peak.
5. The film construction of claim 1, wherein one or more of the
microstructured prismatic elements that have a first peak and a
second peak, each has a pitch, a height, and a valley angle, a
first included angle (alpha), and a second included angle (beta),
wherein: the pitch is from 35 to 55 micrometers; the height is from
45 to 78 micrometers; the aspect ratio is from 1.2 to 1.5; the
valley angle is from 60 to 80 degrees; the angle alpha is from 15
to 25 degrees; and the angle beta is from 5 to 15 degrees.
6. The film construction of claim 1, wherein one or more of the
microstructured prismatic elements that have a first peak and a
second peak, each has a pitch, a height, and a valley angle, a
first included angle (alpha), and a second included angle (beta),
wherein: the pitch is from 35 to 55 micrometers; the height is from
40 to 72 micrometers; the aspect ratio is from 1.1 to 1.3; the
valley angle is from 50 to 70 degrees; the angle alpha is from 18
to 28 degrees; and the angle beta is from 4 to 12 degrees.
7. The film construction of claim 1, wherein H1>H2>H3>0
micrometers, and wherein H3 is less than 6 micrometers
8. The film construction of claim 1, wherein the first peak has an
apex angle B1 and the second peak has an apex angle B2, and wherein
B1<B2.
9. The film construction of claim 1, wherein the film construction
further comprises a diffuser chosen from bulk diffusers, surface
diffusers, embedded diffusers, and combinations thereof.
10. The film construction of claim 1, wherein the film construction
further comprises a diffusing layer adjacent the second major
surface of the cover film.
11. The film construction of claim 1, wherein the adhesive in the
adhesive layer is an UV-curable pressure sensitive adhesive.
12. The film construction of claim 1, wherein the adhesive in the
adhesive layer comprises a diffusing agent and the diffusing agent
is chosen from micro beads and nanoparticles.
13. The film construction of claim 1, wherein the first peak of one
or more of the microstructured prismatic elements penetrates from 1
micrometer to 6 micrometers into the first major surface of the
adhesive layer.
14. The film construction of claim 1, wherein the film construction
further comprises a window film adhesive layer adjacent the second
major surface of the cover film.
15. A glazing unit comprising a film construction of claim 1.
Description
[0001] The present disclosure relates to articles and methods of
making light redirecting film constructions comprising a
microstructured optical film, such as a daylight redirecting film,
bonded to another film. This type of assembly may serve various
purposes. For example, the assembly may protect the microstructured
optical film, provide additional functionality, such as diffusion
or infrared reflection, and/or facilitate attachment of the
microstructured optical film to a mounting surface, such as a
glazing or window pane.
BACKGROUND
[0002] A variety of approaches are used to reduce energy
consumption in buildings. Among those approaches is the more
efficient use of sunlight to provide lighting inside buildings. One
technique for supplying light inside of buildings, such as in
offices, residential buildings, etc. is the redirection of incoming
sunlight. Because sunlight enters windows at a downward angle, much
of this light produces glare and is not useful in illuminating a
room. However, if the incoming downward light rays can be
redirected upward such that they strike the ceiling, the light can
be more usefully employed in lighting the room.
[0003] Light Redirection Films (LRFs), provide natural lighting by
redirecting incoming sunlight upward, onto the ceiling. This can
lead to significant energy savings by reducing the need for
artificial lights. LRFs can consist of linear optical
microstructures that reflect incoming sunlight onto the ceiling.
LRFs are typically installed on the upper clerestory section of
windows 7' and above. A typical configuration is shown on FIG. 1,
where an LRF 101 on a window 110 redirects sunlight 120 upward as
deflected (reflected or refracted) light 124.
[0004] Sunlight that would normally land on the floor can be used
to provide natural lighting by using suitable constructions
involving daylight redirecting films. A comparison of FIG. 2 (no
LRF) with FIG. 3 (LRF present) shows an example of the amount of
light that can be redirected from the floor to the ceiling by the
use of a LRF 201.
[0005] Buildings (residential & commercial) account for about
40% of all energy consumed and lighting represents about 30% of
that energy. Substituting even a fraction of artificial lighting
with natural light can yield significant energy savings. The
Illuminating Engineering Society of North America (IES) has
developed a comprehensive daylight illuminance metric, named
spatial Daylight Autonomy or sDA that characterizes the efficacy of
daylighting systems. An extensive study conducted at several
Department of Defense sites across the U.S. demonstrated that
installation of 3M DRF increases sDA values. In addition to energy
savings, daylighting has soft benefits related to increased worker
productivity, elevated test scores, and improved mood and
energy.
[0006] A problem that is frequently encountered when an area is
illuminated using natural daylight is how to spread the light
adequately and evenly. In the case, for example, in which an area
is being illuminated within a building, there will usually be parts
of that area that are less well-lit than others, and also some
locations where the users of the building are troubled by glare
from the light source. One solution to address this problem is the
use of a diffuser.
[0007] In general, microstructured light redirecting films may be
fragile under certain circumstances because the microstructured
features may be subject to mechanical damage and/or chemical damage
(e.g. window cleaners). One challenge when attempting to protect
the microstructured elements in a LRF is that the lamination
process to add a cover or protective layer can cause damage to
those microstructured elements. The same challenge is present when
attempting to laminate any other type of functional layer or film,
such as a diffuser, to a LRF on the side of the microstructured
elements. Additionally, the presence of an additional layer next to
the LRF may also modify its optical properties and significantly
degrade or modify its light redirecting properties. One of the
goals of the present disclosure is to provide for film
constructions that allow the bonding of a microstructured film,
such as a LRF, to another functional film, without significantly
sacrificing the optical performance of the microstructured
film.
SUMMARY
[0008] The present disclosure is directed, inter alia, to film
constructions comprising a microstructured optical film, such as a
light redirecting film bonded to another film.
[0009] In some embodiments, film constructions of the present
disclosure include light management film constructions comprising
two films: a) a first optical film having a first major surface and
a second major surface opposite the first major surface, wherein
the first major surface comprises a microstructured surface
comprising an ordered arrangement of a plurality of microstructured
prismatic elements, and b) a cover film having a first major
surface and a second major surface opposite the first major
surface, the second major surface disposed adjacent to and making
contact with and bonded to one or more of the microstructured
prismatic elements of the first major structured surface of the
first optical film. A cross section of a microstructured prismatic
element comprises two or more peaks within the same
microstructure.
[0010] The first major surface of the first optical film and second
major surface of the cover film define an enclosed volume partially
occupied by an adhesive layer and by the microstructured prismatic
elements on the first major surface of the first optical film. That
volume defines one or more optically active areas wherein a first
material immediately adjacent to the microstructured prismatic
elements, such as air or any other synthetic alternatives (e.g.,
aerogel), has a difference in refractive index (low with respect to
the microstructured prismatic elements) that allows the
microstructured prismatic elements to redirect light. The
difference in refractive index between the first material (e.g.,
air) and the microstructured prismatic elements allows redirection
of the incident light. Those one or more optically active areas are
bounded by a second material, typically an adhesive, adjacent to a
portion of the microstructured prismatic elements. The presence of
the adhesive immediately adjacent the microstructured prismatic
elements reduces the refraction in the portion of the
microstructured prismatic element that is in contact with the
adhesive if the refractive index of the adhesive is similar to the
refractive index of the microstructured prismatic elements.
[0011] The first optical film and the cover film are bonded via the
adhesive layer when certain portions of the microstructured
prismatic elements (e.g., the tip of one or more of the peaks) on
the first optical film penetrate the adhesive layer. Partial, as
opposed to full, penetration of the tips (e.g., peaks) allows the
presence of a low index interface (e.g., air or low index synthetic
material) for the microstructured prismatic elements to refract
light.
[0012] In some embodiments, the adhesive comprises a plurality of
diffusing agents, such as particles or beads. The particles can
include, for example, silica, alumina, TiO2, or zirconia micro or
nanoparticles to scatter (diffuse) the light. As an alternate
embodiment, spherical beads can be added to the adhesive. If the
beads are matched in refractive index to the adhesive, then the
beads will be transparent, but they can cause a rough surface which
can generate haze and reduce clarity. For example, PMMA beads can
be added to an acrylate adhesive of similar refractive index. In
some embodiments, the particles have a mean diameter in a range
from 0.1 to 100 microns, or 0.5 to 50 microns, or 0.7 to 20
microns. In illustrative embodiments, the particles can be "surface
modified" such that the particles provide a stable dispersion in
which the particles do not agglomerate after standing for a period
of time, such as 24 hours, under ambient conditions.
[0013] In one embodiment, the present disclosure is directed to a
film construction comprising: [0014] a light redirecting film
having a first major surface and a second major surface opposite
the first major surface, [0015] wherein the first major surface of
the light redirecting film comprises a plurality of microstructured
prismatic elements, [0016] wherein one or more of the
microstructured prismatic elements have a first peak and a second
peak, [0017] wherein the first peak has a height H1 and the second
peak has a height H2, [0018] wherein H3 is H1-H2, and H3 is equal
or greater than 1 micron, [0019] an adhesive layer comprising an
adhesive, wherein the adhesive layer has a first major surface and
a second major surface opposite the first major surface, [0020] a
cover film having a first major surface and a second major surface
opposite the first major surface, wherein the first peak of one or
more of the microstructured prismatic elements penetrates at least
partially into the first major surface of the adhesive layer,
wherein the second major surface of the adhesive layer is adjacent
to the first major surface of the cover film.
[0021] In other embodiments, the film construction comprises:
[0022] a light redirecting film having a first major surface and a
second major surface opposite the first major surface, [0023]
wherein the first major surface of the light redirecting film
comprises a plurality of microstructured prismatic elements, [0024]
wherein one or more of the microstructured prismatic elements have
a first peak and a second peak, [0025] wherein the first peak has a
height H1 and the second peak has a height H2, [0026] wherein H3 is
H1-H2, and H3 is from 1 microns to 8 microns, [0027] an adhesive
layer comprising an adhesive, wherein the adhesive layer has a
first major surface and a second major surface opposite the first
major surface, [0028] a cover film having a first major surface and
a second major surface opposite the first major surface, [0029] a
diffusion layer, [0030] wherein when the film construction is in a
vertical position, the first peak of the microstructured prismatic
element is positionally located above the second peak, [0031]
wherein the first peak has an apex angle B1 and the second peak has
an apex angle B2, and wherein B1<B2, [0032] wherein the first
peak of one or more of the microstructured prismatic elements
penetrates at least partially into the first major surface of the
adhesive layer, [0033] wherein the first major surface of the light
redirecting film is bonded to the first major surface of the
adhesive layer, [0034] wherein the second major surface of the
adhesive layer is bonded to the first major surface of the cover
film.
[0035] In other embodiments, the present disclosure is directed to
window films that comprise a film constructions as described above.
In yet other embodiments, the present disclosure is directed to
windows comprising film constructions as described herein.
[0036] All scientific and technical terms used herein have meanings
commonly used in the art unless otherwise specified. The
definitions provided herein are to facilitate understanding of
certain terms used frequently in this application and are not meant
to exclude a reasonable interpretation of those terms in the
context of the present disclosure.
[0037] Unless otherwise indicated, all numbers in the description
and the claims expressing feature sizes, amounts, and physical
properties used in the specification and claims are to be
understood as being modified in all instances by the term "about."
Accordingly, unless indicated to the contrary, the numerical
parameters set forth in the foregoing specification and attached
claims are approximations that can vary depending upon the desired
properties sought to be obtained by those skilled in the art
utilizing the teachings disclosed herein. At the very least, and
not as an attempt to limit the application of the doctrine of
equivalents to the scope of the claims, each numerical parameter
should at least be construed in light of the number of reported
significant digits and by applying ordinary rounding techniques.
Notwithstanding that the numerical ranges and parameters used in
describing the broad scope of the invention are approximations, the
numerical values in the specific examples are reported as precisely
as possible. Any numerical value, however, inherently contains
certain errors necessarily resulting from the standard deviations
found in their respective testing measurements.
[0038] The recitation of numerical ranges by endpoints includes all
numbers subsumed within that range (e.g. a range from 1 to 5
includes, for instance, 1, 1.5, 2, 2.75, 3, 3.80, 4, and 5) and any
range within that range.
[0039] As used in this specification and the appended claims, the
singular forms "a", "an", and "the" encompass embodiments having
plural referents, unless the content clearly dictates otherwise. As
used in this specification and the appended claims, the term "or"
is generally employed in its sense including "and/or" unless the
content clearly dictates otherwise.
[0040] The term "adhesive" as used herein refers to polymeric
compositions useful to adhere together two components
(adherents).
[0041] The term "bonded" as used herein refers to an element that
has been adhesively attached to another element. Any type of
adhesive can be used to bond to elements together. The term
"bonded" can be used to describe adhesive attachment of one element
(for example a layer or an individual microstructured prismatic
element) to an adhesive or adhesive layer or to another element
adhesively attached to the adhesive or adhesive layer. For example,
in FIG. 11, the microstructured prismatic element (or in general
terms the film comprising the microstructured prismatic element) is
bonded (via the tip of each peak) to the adhesive layer, but it can
also be said that the microstructured prismatic element (or the
film) is bonded to the substrate (e.g., a cover film).
[0042] The term "penetrates" or "penetrating" as used herein in the
context of a portion of a microstructured prismatic element
penetrating an adhesive layer refers to a portion of the
microstructured prismatic element being embedded in the adhesive
layer, which would allow, once the adhesive is cured, set,
hardened, etc., the microstructured prismatic element (or a film
containing the microstructured prismatic element) to be bonded to
the adhesive layer or to another film or substrate (e.g., a cover
film). For example, FIGS. 12 and 13 show that the tip of each peak
of the microstructured prismatic element penetrate the adhesive
layer. The portion of the microstructured prismatic element that
penetrates the adhesive later is defined as the "bonding portion"
of the microstructured prismatic element. FIGS. 14 A and B show
that the microstructured prismatic element (or the light
redirecting film) is bonded to the adhesive layer (or to the
substrate bonded to the adhesive layer) by means of the tips of the
peaks of the microstructured prismatic element having penetrated
the adhesive layer, creating surface contact between the prismatic
element and the adhesive.
[0043] The term "window film adhesive layer" as used herein refers
to a layer comprising an adhesive suitable to bond a film to a
window or glazing, such as, for example, a pressure sensitive
adhesive.
[0044] The term "adjacent" as used herein refers to the relative
position of two elements, such as layers in a film construction,
that are close to each other and may or may not be necessarily in
contact with each other and may have one or more layers separating
the two elements, as understood by the context in which "adjacent"
appears.
[0045] The term "immediately adjacent" as used herein refers to the
relative position of two elements, such as layers in a film
construction, that are in physical contact and immediately next to
each other without having any other layers separating the two
elements, as understood by the context in which "immediately
adjacent" appears. The term "immediately adjacent," however,
encompasses situations where one or both elements have been treated
with a primer, or whose surface has been modified to affect the
properties thereof, such as etching, embossing, etc., or by surface
treatments, such as corona or plasma treatment, etc., that may
improve adhesion.
[0046] The term "construction" or "assembly" are used
interchangeably in this application when referring to a multilayer
film, in which the different layers can be coextruded, laminated,
coated one over another, or any combination thereof.
[0047] The terms "pitch," "height," "valley angle," "first included
angle alpha," "second included angle beta," "apex angle," and
"aspect ratio" in connection with a microstructured prismatic
element are defined as follows, with reference to FIG. 5. The pitch
is the length of side A. The height is the height of the tallest
peak (H1), which in FIG. 5 is the peak formed by sides D and E.
That is, the height of the microstructure is the horizontal
distance from the Y axis to the apex of the tallest peak, which in
FIG. 5 is formed by sides D and E. The valley angle is the angle
407. The first included angle, or angle alpha, is the angle "a."
The second included angle, or angle beta, is the angle "b." The
apex angle is the internal angle of a peak. In FIG. 5, the apex
angle for the peak formed by sides B and C is the angle "d" and the
apex angle for the peak formed by sides D and E is the angle "c."
The aspect ratio is the ratio between the height of the
microstructured prismatic element and the pitch (H1/A).
[0048] The term "optical film" as used herein refers to films that
are at least optically transparent and which may have high
transmission of visible light, may be optically clear or
transluscent and may also produce additional optical effects.
Examples of additional optical effects include, for example, light
diffusion, light polarization or reflection of certain wavelengths
of light. The optical film may be any suitable film that has high
optical transmission in the visible light region of the spectrum.
An optical film may have a visible light transmission greater than
20%, greater than 50%, or in certain preferred embodiments, greater
than 80%. The optical film may be a single layer film or a
multilayer film construction.
[0049] The term "ordered arrangement" as used herein to describe a
plurality of structures, refers to a regular, repeated pattern of
structures.
[0050] The term "substantially straight" in the context of a side
of a microstructured prismatic element as used herein refers to a
side that is mostly straight but that could deviate from a straight
line due to inaccuracies introduced by manufacturing processes or
may intentionally have minor curvature (i.e. large radius) to
spread redirected (refract) light.
[0051] The term "light redirecting layer" as used herein refers to
a layer that comprises microstructured prismatic elements.
[0052] The term "light redirecting film" or "light directing film"
as used herein refers to a film that comprises one or more light
redirecting layers and optionally other additional layers, such as
substrates or other functional layers. A daylight redirecting film
is an example of a light redirecting film.
[0053] Light redirection, in general, may be called daylight
redirection, sunlight redirection, or solar light redirection when
the source of light is the sun.
[0054] The term "film" as used herein refers, depending on the
context, to either a single layer article or to a multilayer
construction, where the different layers may have been laminated,
co-extruded, coated, or any combination thereof.
[0055] The term "microstructured prismatic element," sometimes
referred to in the short form as "microstructures," as used herein
refers to an engineered optical element, wherein at least 2
dimensions of the features are microscopic, that redirects input
light with certain angular characteristics into output light with
certain angular characteristics. In certain embodiments, the height
of the microstructured prismatic element is less than 1000 microns.
A microstructured prismatic element of the present disclosure may
comprise a multipeak structure, such as a double peak structure,
structures comprising one or more curved facets, or combinations
thereof. The microstructured prismatic elements, including all of
their physical and optical characteristics (e.g., glare, TIR
angles, etc.), are disclosed in PCT application titled "Room-Facing
Light Redirecting Film with Reduced Glare," published as WO
2016/064667 and PCT application titled "Sun-Facing Light
Redirecting Film with Reduced Glare," published as WO 2016/064621,
are hereby incorporated by reference. Examples of microstructured
prismatic elements 410 are shown in FIGS. 4 to 9.
[0056] The term "diffusing agent" as used herein refers to features
or additives incorporated into an article that increase the angular
spread of light passing through the same article, such as, for
example, micro beads or nanoparticles.
[0057] The term "diffusing layer," "diffusive element," or
"diffuser" are interchangeable in this disclosure and as used
herein refer to an element in a film construction that provides
diffusion of visible light. The diffusive element may be a layer or
coating having diffusive properties with respect to visible light
or a surface treatment on a layer of the film constructions of the
present disclosure that provides diffusive properties to the
treated surface.
[0058] The term "positionally located above" as used herein refers
to the relative position of one peak in a microstructured prismatic
element with respect to another peak in the same microstructured
prismatic element. When the microstructured prismatic element is in
a vertical position (see, e.g., microstructured prismatic element
410 in FIG. 4 or 5) and its base (side A) is parallel to a vertical
axis (e.g., a y-axis) the peak with the apex located at the longest
distance from the x-axis in the y-direction is the peak that is
positionally located above the other peak. In this case, the
location of the x and y axes is chosen so that the microstructured
prismatic element is fully in the quadrant where both x and y have
positive values. For example, in FIG. 4, the peak defined by sides
C and D (apex angle "d") is positionally located above the peak
defined by sides D and E (apex angle "c"). In FIG. 7, the peak with
an apex angle of 41.0.degree. is positionally located above the
peak with an apex angle of 61.3.degree..
[0059] As used herein, the index of refraction of a material 1
("RI1") is said to "match" the index of refraction of a material 2
("RI2") if the value RI' is within +/-5% of RI2.
[0060] For the following definitions of "room-facing" and
"sun-facing," it is assumed that a light redirecting layer has a
first major surface and second major surface opposite the first
major surface and that the first major surface of the light
redirecting film comprises microstructured prismatic elements.
[0061] As used herein, the term "room-facing," in the context of a
light redirecting film or a construction comprising a light
redirecting film, refers to a film or construction where the
incident light rays pass through the major surface of the light
redirecting film not containing the microstructured prismatic
elements before they pass through the major surface that contains
the microstructured prismatic elements. In the most typical
configuration, when the light redirecting film is located on an
exterior window (i.e., when the window faces the exterior of a
building), the microstructured prismatic elements in a
"room-facing" configuration are oriented facing the interior of the
room. However, the term "room-facing," as defined herein can also
refer to configurations where the light redirecting film is on a
glazing, or other kind of substrate, that does not face the
exterior of the building, but is in between two interior areas.
[0062] As used herein, the term "sun-facing," in the context of a
light redirecting film or a construction comprising a light
redirecting film, refers to a film or construction where the
incident light rays pass through the major surface of the light
redirecting film containing the microstructured prismatic elements
before they pass through the other major surface (the major surface
not containing the microstructured prismatic elements). In the most
typical configuration, when the light redirecting film is located
on an exterior window (i.e., when the window faces the exterior of
a building), the microstructured prismatic elements in a
"sun-facing" configuration are oriented facing the sun. However,
the term "sun-facing," as defined herein can also refer to
configurations where the light redirecting film is on a glazing
that does not face the exterior of the building, but is in between
two interior areas.
[0063] As used herein, the term "sealing" or "sealed" when
referring to an edge of an article of this disclosure means
blocking the ingress of certain undesired elements such as
moisture, air, and/or other contaminants.
[0064] The term "setting" or "curing" as used herein refers to
transforming a material from an initial state to its final desired
state with different properties such as flow, stiffness, etc.,
using physical (e.g. temperature, either heating or cooling),
chemical, or radiation (e.g. UV or e-beam radiation) means.
[0065] The term "visible light" as used herein refers to refers to
radiation in the visible spectrum, which in this disclosure is
taken to be from 380 nm to 700 nm.
[0066] The term "punch through" as used herein refers to light that
transmits directly (or specularly) through the light directing film
construction without redirection. Another embodiment of punch
through is light that is only redirected at +5 or -5 degrees from
specular transmission. Punch through can cause glare, especially
with light that is directed shallow and down from the horizontal
position that the light impinges on the LRF.
BRIEF DESCRIPTION OF THE DRAWINGS
[0067] FIG. 1 is a typical configuration showing the use of a light
redirecting film, demonstrating light redirection after the light
passed through a room-facing light redirecting layer.
[0068] FIG. 2 shows light entering a room through a window without
a light redirecting film.
[0069] FIG. 3 shows an example of the amount of light that can be
redirected from the floor to the ceiling by the use of a light
redirecting film construction.
[0070] FIG. 4 shows a schematic diagram of a room-facing
microstructured prismatic element of the present disclosure.
[0071] FIG. 5 shows a schematic diagram of a sun-facing
microstructured prismatic element of the present disclosure.
[0072] FIG. 6 shows a cross-section of an embodiment of a
room-facing microstructured prismatic element.
[0073] FIG. 6(a) shows the room-facing microstructured prismatic
element of FIG. 6 with the pitch, height, and aspect ratio of 1.23
as indicated.
[0074] FIG. 7 shows a cross-section of another embodiment of a
room-facing microstructured prismatic element with aspect ratio of
1.31.
[0075] FIG. 8 shows a cross-section of another embodiment of a
room-facing microstructured prismatic element with aspect ratio of
1.36
[0076] FIG. 9 shows a cross-section of another embodiment of a
room-facing microstructured prismatic element with aspect ratio of
1.38.
[0077] FIG. 10 is a cross-section of a room in which the upper
portion of the window is outfitted with a light redirecting film,
and shows the fraction of the light that is downwardly deflected as
direct glare.
[0078] FIG. 11 is a cross-section showing a microstructured
prismatic element embedded in a layer of adhesive (0.degree. to
-15.degree.).
[0079] FIG. 12 is a cross-section showing that the amount of
adhesive displaced by a facet of the embedded microstructured
prismatic element is proportional to the slope of the facet.
[0080] FIG. 13 is a photomicrograph of an embodiment of a light
redirecting construction illustrating how light is redirected from
a surface of a microstructured prismatic element with an air
interface, but light impinging on a microstructured prismatic
element at an adhesive interface is not redirected ("punch
through").
[0081] FIG. 14 shows (a) another view of the embodiment of FIG. 13
and (b) the adhesive displaced by the facets of the microstructured
prismatic element.
[0082] FIG. 15 shows photomicrographs illustrating the effect of
adhesive thickness on the depth that microstructured prismatic
elements are embedded in the adhesive and corresponding conoscopic
plots illustrating increasing "punch through" with increasing
adhesive thickness.
[0083] FIG. 16 illustrates the effect of microstructured prismatic
element immersion in adhesive on "punch through".
[0084] FIG. 17 illustrates the effect of microstructured prismatic
element immersion in adhesive on peel strength.
[0085] FIG. 18 shows two different modified microstructured
prismatic element based on the same initial structure. The top
panel shows a microstructured prismatic element where the top peak
extended and immersed into adhesive and the bottom panel shows a
microstructured prismatic element where the bottom peak extended
and immersed into adhesive.
[0086] FIG. 19 is a cross-section showing two microstructured
prismatic elements having different relative peak heights.
[0087] FIG. 20 shows a plano view of an embodiment of a light
redirecting film construction that further comprises an edge
seal.
[0088] FIG. 21 illustrates a process that can be used to make a
microstructured prismatic film.
[0089] FIG. 22 illustrates a process that can be used to make a
light redirecting film construction of the present invention.
[0090] FIG. 23 shows a cross-section of another embodiment of a
room-facing microstructured prismatic element having three
peaks.
[0091] FIG. 24 shows a cross-section of another embodiment of a
room-facing microstructured prismatic element having curved
facets.
[0092] FIG. 25 shows a cross-section of another embodiment of a
room-facing microstructured prismatic element having a curved
facets.
[0093] FIG. 26 shows another embodiment of a light redirecting film
construction.
[0094] FIG. 27 shows another embodiment of a light redirecting film
construction.
[0095] FIG. 28 shows another embodiment of a light redirecting film
construction.
[0096] FIG. 29(a) shows an embodiment of a light redirecting film
construction having room-facing microstructured prismatic
elements.
[0097] FIG. 29(b) shows an embodiment of a light redirecting film
construction having sun-facing microstructured prismatic
elements.
[0098] FIG. 30 shows another embodiment of a light redirecting film
construction.
[0099] FIG. 31 shows another embodiment of a light redirecting film
construction.
[0100] FIG. 32 shows another embodiment of a light redirecting film
construction.
[0101] FIG. 33 shows the effect of adhesive thickness on the amount
of direct glare produced as a function of sun elevation angle.
[0102] FIG. 34 shows modeled punch-through glare vs. sun elevation
angle for the two microstructured prismatic elements described in
FIG. 18.
[0103] FIG. 35 shows the measured color coordinates of two
embodiments of the invention relative to a window with no film
installed. The length of the lines connecting each point to the
original input color (circle) is equivalent to the color shift for
each measurement.
ELEMENT NUMBERS
[0104] 101 Light Redirecting Film Construction [0105] 110 Window
[0106] 120 Sunlight [0107] 121 Cover film [0108] 122 Guiding roller
[0109] 123 Nip roller [0110] 124 Resin composition [0111] 125
Patterned tool roll [0112] 126 Coating die [0113] 127
Microstructured tool surface [0114] 129 Radiation source [0115] 130
Radiation source [0116] 131 Film with microstructured prismatic
elements [0117] 201 Light Redirecting Film Construction [0118] 401
First major surface of the optical substrate [0119] 402 Second
major surface of the optical substrate [0120] 403 Optical substrate
[0121] 404 Reference X-axis [0122] 405 Reference Y-axis [0123] 406
Reference plane [0124] 407 Valley angle [0125] 408 Light incidence
angle [0126] 410 Microstructured prismatic element [0127] 412
Sunlight [0128] 1220 Sunlight deflected downward [0129] 1240
Sunlight deflected upward [0130] 1502 Guiding roll [0131] 1504
Microstructured prismatic film [0132] 1506 Unwind roll [0133] 1508
Guiding roll [0134] 1512 Unwind roll [0135] 1514 Stripped film
[0136] 1516 Cover film [0137] 1518 Pinch roller pair [0138] 1520
Coater [0139] 1522 Adhesive layer [0140] 1526 UV lamp [0141] 1528
Layered film [0142] 1542 Collection roll
[0143] In the following description, reference is made to the
accompanying Figures herein described. In certain cases, the
Figures may depict, by way of illustration, several specific
embodiments of the present disclosure. It is to be understood that
other embodiments different from those explicitly depicted in the
Figures are contemplated and may be made without departing from the
scope or spirit of the present disclosure. The following detailed
description, therefore, is not to be taken in a limiting sense.
DETAILED DESCRIPTION
[0144] The disclosure in the present disclosure is exemplified by
referring to light, or daylight redirecting films and light or
daylight redirecting layers as being part of the overall
construction, but the concepts and subject matter taught and
claimed in this application can extend to other microstructured
optical films that are not light redirecting films.
[0145] In general, the present disclosure relates to film
constructions where two films are bonded to each other and at least
one of the films comprises a microstructured optical film. In a
typical example, the microstructured prismatic optical film may be
a light redirecting film and the second film is a cover film.
Bonding of the structured surface of the optical film to an
opposing surface of the cover film occurs via a layer of adhesive,
wherein certain portions of the surface features of the
microstructured prismatic elements of the microstructured optical
film penetrate partially into the adhesive to a depth that is less
than the height of the microstructured prismatic element. The
microstructured prismatic elements of the present disclosure have
two or more peaks. In some embodiments, only one peak of a
microstructured prismatic element penetrates partially into the
adhesive. In other embodiments, both peaks (e.g., in a two peak
microstructured prismatic element) penetrate the adhesive. Under
certain circumstances, it is preferable that only one peak of the
multi-peak microstructured prismatic element penetrates into the
adhesive in order to increase light redirection.
[0146] Typically, the adhesive layer has a thickness less than the
associated heights of the microstructured prismatic element that
penetrates the adhesive so as to leave a gap between the adhesive
layer and portions of the light redirecting layer comprising the
microstructured prismatic elements.
[0147] Full penetration of the microstructured prismatic element
into the adhesive would reduce or eliminate the needed difference
in refractive index between the microstructured prismatic element
and the surrounding low index material (e.g., air) such that light
redirection would be significantly adversely affected.
[0148] The type of bonding disclosed and taught in this application
between two films (e.g., a light redirecting film and a cover film)
refers to bonding only via selected areas in the light redirecting
film (such as, e.g., the tips of peaks in the microstructured
prismatic elements) in order to increase the light redirecting
function (or a suitable function in other microstructured optical
films) of the film. As will be shown below, because the presence of
the adhesive contacting the microstructured prismatic elements
decreases the ability to redirect light as the bonding portions of
the microstructured prismatic elements (e.g., portions of the
peaks) penetrate into the adhesive, there is a functional balance
between the size and number of the bonding portions and the
strength of the bond between the light redirecting film and the
cover film. That is, as the size and number of the bonding portions
increases, the strength of the bond increases, which is beneficial,
but there is also less area left to perform the light redirecting
function of the original light redirecting film. Conversely, as the
size of the bonding portions decreases, the higher amount of light
is redirected, but the size of the area available for bonding
decreases as does the strength of the bond between the two
films.
[0149] If the refractive index of the adhesive and the prismatic
element are similar, the light will not be redirected and will
punch through the film, and can produce glare. As the size and
number of the bonding portions increases, the amount of punch
through will increase.
[0150] Multi-peaked microstructured prismatic elements
[0151] In general, in daylight redirecting applications it is
preferable that the incident light be redirected up and at shallow
angles from the horizontal position that the light impinges on the
LRF. This distribution provides light deeper within the interior
spaces and away from windows where natural light is in short
supply.
[0152] The light output from a light directing film is shown in
FIG. 10. In general, it is desired to redirect the light upward and
deep into the room. Light that is not redirected (punch-through) or
light that is directed downward is not desirable as it will
contribute to glare. The inventors have designated different upward
and downward regions to model and measure light redirection to
optimize performance. For example, as shown in FIG. 10 is a region
designated as "Direct Glare" for angles from 0 degrees to -15
degrees below horizontal. In addition to improving the redirection
performance, the inventors have considered other design constraints
imposed to ensure that the microstructured prismatic elements can
be made using a viable manufacturing process.
[0153] With respect to a microstructured prismatic element having
two peaks, each peak may have different included angles and
different heights. The inventors have taken into account the
bonding process in order to design improved microstructured
prismatic elements. For example, the inventors have found that
during lamination of the daylight redirecting film and the cover
film, the direction of adhesive flow is constrained by the tip
immersion points (FIG. 11).
[0154] Typically, adhesive flows along the facet depending on which
side of the tip immersion point it lies. The direction of adhesive
flow along the four facets of a two-peaked microstructured
prismatic element is indicated by the arrows in FIG. 11. As
mentioned above, adhesive flow along the facets leads to excessive
adhesive along the facets and further degradation of the optical
performance. The inventors have found that the magnitude of
adhesive flow is proportional to the volume of adhesive displaced
by a certain facet as shown in FIG. 12.
[0155] The inventors calculated the volume of adhesive displaced by
a facet as a function of the area embedded within the adhesive. The
embedded areas for the four facets shown in FIG. 12 are: m=1.22,
n=7.05, o=3.62, and p=2.40). Based on these areas, the more gentle
facets (n and o) are expected to displace more adhesive than
steeper ones (m and p). Based on this model the inventors expect
that the optical performance along those facets would be less
favorable than along the steeper ones. The inventor's model has
been verified using the structure shown in FIGS. 14(a) and (b).
[0156] In this instance, the structure was embedded into a film
with a 6 um thick adhesive. The degree of adhesive flow observed
along each facet is proportional to the volume of adhesive
displaced which is directly related to its slope angle. As shown in
FIG. 14(b) more gently slopes (2, 3) exhibit significantly more
adhesive flow (white areas) along their facets than steeper slopes
(1, 4). In FIGS. 14(a) and (b), the dark or black areas surrounding
the microstructured prismatic element represent air, whose presence
around the microstructured prismatic element aids in the refraction
of light characteristic of a daylight redirecting film. As can be
seen in the figure, there is significant adhesive build up in the
valley defined by slopes 2 and 3. Depending on the adhesive
thickness this valley can be almost completely embedded in
adhesive, which would result in an increase in punch through glare
as shown in FIG. 15.
[0157] Adhesive flow into the structure as a function of adhesive
thickness ranging from 3 to 8 um is shown in FIG. 15. Using a 3 um
thick adhesive, the structure is barely embedded in the adhesive,
whereas with an 8 um thick adhesive, the valley is almost
completely filled with adhesive. A corresponding increase in punch
through is observed with increasing structure immersion as shown in
the conoscopic plots of FIG. 15 and in FIG. 16.
[0158] However, while reducing tip immersion improves optics by
reducing punch-through it comes at the price of reduced peel
strength between the films in the laminate. Reduced peel strength
can adversely affect durability of the film. The effect of tip
immersion on peel force is shown in FIG. 17. As can be seen in that
figure, the peel increases by more than a factor of three as the
adhesive thickness increases from 3 um to 8 um.
[0159] Based on results from the inventor's model and observations
from empirical testing, the inventors have determined certain
guidelines regarding the design and orientation of microstructured
prismatic elements suitable for lamination methods involving tip
bonding when using asymmetric multi-peaked redirection
microstructured prismatic elements:
[0160] 1. It is preferable that only a single peak be immersed in
the adhesive
[0161] 2. It is preferable that the "steeper" peak (that is the
peak with the smaller apex angle) should be immersed in the
adhesive.
[0162] These concepts are illustrated in FIG. 18, which shows the
base microstructured prismatic element from FIG. 14 in grey shading
Two modified structures in darker shading are shown:
[0163] a. A top (steeper) peak taller by 5 um
[0164] b. Bottom (more gentle) peak taller by 5 um
[0165] In both cases the structures were modeled to be immersed 4
um into the adhesive. The punch through glare was then calculated
at various elevation angles as shown in FIG. 35
[0166] As seen in FIG. 35, immersing the steeper, top peak results
in significantly lower punch through glare at all of the elevation
angles tested. Therefore, the inventors have determined additional
guidelines to reduce punch through glare for the type of tip bonded
film constructions of the present disclosure, concluding that it is
preferable to:
[0167] a) Immerse the steepest peak in a multi-peaked asymmetrical
redirecting microstructured prismatic element into the adhesive
[0168] b) Avoid immersing the bottom peak into the adhesive. The
inventors have found that the bottom facet is highly important in a
redirecting microstructured prismatic element given that total
internal reflection of the incoming light occurs at this surface.
In the inventors view, the upper peaks/facets can be immersed into
the adhesive with lesser impact on optical performance.
[0169] The inventors designed a steeper, upper (sun-facing, closer
to ceiling) microstructured prismatic element with a peak 4 um
taller than the lower, gentler peak. In a tip-bonded construction
this peak would be partially immersed in the adhesive while the
lower one would not be immersed. In this preferred orientation the
impact of tip immersion on optical performance would be reduced.
This is just one example of a microstructured prismatic element
that could be used for tip-bonding film construction.
[0170] The type of construction proposed in this application may
serve various purposes. For example, the assembly may protect the
microstructured prismatic elements on the light redirecting film,
the second film to which the light redirecting film is bonded may
provide additional functionality, such as diffusion, infrared
reflection, control of visible light transmission, etc., and the
construction may also facilitate attachment of the light
redirecting film to a mounting surface, such as a window.
[0171] Bonding the two films offers other significant advantages.
For example, the resulting construction can have improved handling,
rigidity, and provide the ability to attain thinner final
constructions.
[0172] Basic Constructions
[0173] In some embodiments, the present disclosure is directed to
film constructions as described below. In one embodiment, the
disclosure is directed to a film construction comprising: [0174] a
light redirecting film having a first major surface and a second
major surface opposite the first major surface, [0175] wherein the
first major surface of the light redirecting film comprises a
plurality of microstructured prismatic elements, [0176] wherein one
or more of the microstructured prismatic elements have a first peak
and a second peak, [0177] wherein the first peak has a height H1
and the second peak has a height H2, [0178] wherein H3 is H1-H2,
and H3 is equal or greater than 1 micron, [0179] an adhesive layer
comprising an adhesive, wherein the adhesive layer has a first
major surface and a second major surface opposite the first major
surface, [0180] a cover film having a first major surface and a
second major surface opposite the first major surface, [0181]
wherein the first peak of one or more of the microstructured
prismatic elements penetrates at least partially into the first
major surface of the adhesive layer, wherein the second major
surface of the adhesive layer is adjacent to the first major
surface of the cover film. In another embodiment, the disclosure is
directed to a film construction comprising: [0182] a light
redirecting film having a first major surface and a second major
surface opposite the first major surface, [0183] wherein the first
major surface of the light redirecting film comprises a plurality
of microstructured prismatic elements, [0184] wherein one or more
of the microstructured prismatic elements have a first peak and a
second peak, [0185] wherein the first peak has a height H1 and the
second peak has a height H2, [0186] wherein H3 is H1-H2, and H3 is
from 1 microns to 8 microns, [0187] an adhesive layer comprising an
adhesive, wherein the adhesive layer has a first major surface and
a second major surface opposite the first major surface, [0188] a
cover film having a first major surface and a second major surface
opposite the first major surface, [0189] a diffusion layer, [0190]
wherein when the film construction is in a vertical position, the
first peak of the microstructured prismatic element is positionally
located above the second peak, [0191] wherein the first peak has an
apex angle B1 and the second peak has an apex angle B2, and wherein
B1<B2, [0192] wherein the first peak of one or more of the
microstructured prismatic elements penetrates at least partially
into the first major surface of the adhesive layer, [0193] wherein
the first major surface of the light redirecting film is bonded to
the first major surface of the adhesive layer, [0194] wherein the
second major surface of the adhesive layer is bonded to the first
major surface of the cover film. In another embodiment, the
disclosure is directed to a film construction comprising: [0195] a
light redirecting film having a first major surface and a second
major surface opposite the first major surface, [0196] wherein the
first major surface of the light redirecting film comprises a
plurality of microstructured prismatic elements, [0197] wherein one
or more of the microstructured prismatic elements have a first
peak, a second peak, and a third peak, [0198] wherein the first
peak has a height H1, the second peak has a height H2, the third
peak has a height H3, [0199] wherein H1>H2 and H1>H3, [0200]
wherein H4 is H1-H2, and H5 is H1-H3, and wherein H4 is from 2
microns to 10 microns and H5 is from 2 microns to 10 microns,
[0201] an adhesive layer comprising an adhesive, wherein the
adhesive layer has a first major surface and a second major surface
opposite the first major surface, [0202] a cover film having a
first major surface and a second major surface opposite the first
major surface, [0203] wherein when the film construction is in a
vertical position, the first peak of the microstructured prismatic
element is: a) positionally located above the second peak, b)
positionally located above the third peak, or positionally located
above both the second peak and the third peak, [0204] wherein the
first peak has an apex angle B1, the second peak has an apex angle
B2, and the third peak has an apex angle B3, wherein B1<B2 and
B1<B3, [0205] wherein the first peak of one or more of the
microstructured prismatic elements penetrates at least partially
into the first major surface of the adhesive layer, [0206] wherein
the first major surface of the light redirecting film is bonded to
the first major surface of the adhesive layer, [0207] wherein the
second major surface of the adhesive layer is bonded to the first
major surface of the cover film. In another embodiment, the
disclosure is directed to a film construction comprising: [0208] a
light redirecting film having a first major surface and a second
major surface opposite the first major surface, [0209] wherein the
first major surface of the light redirecting film comprises a
plurality of microstructured prismatic elements, [0210] wherein one
or more of the microstructured prismatic elements have three or
more peaks, [0211] wherein each of the peaks has a height, [0212]
wherein the first peak has a height larger than the height of each
of the rest of the peaks, [0213] wherein the difference between the
height of the first peak and the height of each of the rest of the
peaks is, independently from each other, from 2 microns to 10
microns, [0214] an adhesive layer comprising an adhesive, wherein
the adhesive layer has a first major surface and a second major
surface opposite the first major surface, [0215] a cover film
having a first major surface and a second major surface opposite
the first major surface, [0216] wherein when the film construction
is in a vertical position, the first peak of the microstructured
prismatic element is positionally located above at least one of the
rest of the peaks, [0217] wherein each of the peaks has an apex
angle, and wherein the apex angle of the first peak is smaller than
the apex angle of each of the rest apex angles, [0218] wherein the
first peak of one or more of the microstructured prismatic elements
penetrates at least partially into the first major surface of the
adhesive layer, [0219] wherein the first major surface of the light
redirecting film is bonded to the first major surface of the
adhesive layer, [0220] wherein the second major surface of the
adhesive layer is bonded to the first major surface of the cover
film.
[0221] Other embodiments of the film constructions of the present
disclosure include the following: [0222] A film construction
comprising the following elements adjacent to each other in the
specified order: (a) a diffusing layer, (b) a light redirecting
film, (c) an adhesive layer, and (d) a cover film, [0223] A film
construction comprising the following elements immediately adjacent
to each other in the specified order: (a) a diffusing layer, (b) a
light redirecting film, (c) an adhesive layer, and (d) a cover
film, [0224] A film construction comprising the following elements
adjacent to each other in the specified order: (a) a diffusing
layer, (b) a light redirecting film, (c) an adhesive layer, (d) a
cover film, (e) and a window film adhesive, [0225] A film
construction comprising the following elements immediately adjacent
to each other in the specified order: (a) a diffusing layer, (b) a
light redirecting film, (c) an adhesive layer, (d) a cover film,
(e) and a window film adhesive, [0226] A film construction
comprising the following elements adjacent to each other in the
specified order: (a) a diffusing layer, (b) a light redirecting
film, (c) an adhesive layer, (d) a cover film, (e) a window film
adhesive, and (f) a liner, [0227] A film construction comprising
the following elements immediately adjacent to each other in the
specified order: (a) a diffusing layer, (b) a light redirecting
film, (c) an adhesive layer, (d) a cover film, (e) a window film
adhesive, and (f) a liner, [0228] A film construction comprising
the following elements adjacent to each other in the specified
order: (a) a microreplicated diffuser coating, (b) a light
redirecting film, (c) an adhesive layer, and (d) a cover film,
[0229] A film construction comprising the following elements
immediately adjacent to each other in the specified order: (a) a
microreplicated diffuser coating, (b) a light redirecting film, (c)
an adhesive layer, and (d) a cover film, [0230] A film construction
comprising the following elements adjacent to each other in the
specified order: (a) a microreplicated diffuser coating, (b) a
light redirecting film, (c) an adhesive layer, (d) a cover film,
(e) and a window film adhesive, [0231] A film construction
comprising the following elements immediately adjacent to each
other in the specified order: (a) a microreplicated diffuser
coating, (b) a light redirecting film, (c) an adhesive layer, (d) a
cover film, (e) and a window film adhesive, [0232] A film
construction comprising the following elements adjacent to each
other in the specified order: (a) a microreplicated diffuser
coating, (b) a light redirecting film, (c) an adhesive layer, (d) a
cover film, (e) a window film adhesive, and (f) a liner, [0233] A
film construction comprising the following elements immediately
adjacent to each other in the specified order: (a) a
microreplicated diffuser coating, (b) a light redirecting film, (c)
an adhesive layer, (d) a cover film, (e) a window film adhesive,
and (f) a liner, [0234] A film construction comprising the
following elements adjacent to each other in the specified order:
(a) a coating with diffusing agents, (b) a light redirecting film,
(c) an adhesive layer, and (d) a cover film, [0235] A film
construction comprising the following elements immediately adjacent
to each other in the specified order: (a) a coating with diffusing
agents, (b) a light redirecting film, (c) an adhesive layer, and
(d) a cover film, [0236] A film construction comprising the
following elements adjacent to each other in the specified order:
(a) a coating with diffusing agents, (b) a light redirecting film,
(c) an adhesive layer, (d) a cover film, (e) and a window film
adhesive, [0237] A film construction comprising the following
elements immediately adjacent to each other in the specified order:
(a) a coating with diffusing agents, (b) a light redirecting film,
(c) an adhesive layer, (d) a cover film, (e) and a window film
adhesive, [0238] A film construction comprising the following
elements adjacent to each other in the specified order: (a) a
coating with diffusing agents, (b) a light redirecting film, (c) an
adhesive layer, (d) a cover film, (e) a window film adhesive, and
(f) a liner, [0239] A film construction comprising the following
elements immediately adjacent to each other in the specified order:
(a) a coating with diffusing agents, (b) a light redirecting film,
(c) an adhesive layer, (d) a cover film, (e) a window film
adhesive, and (f) a liner, [0240] A film construction comprising
the following elements adjacent to each other in the specified
order: (a) a diffusing layer, (b) a light redirecting film, (c) an
adhesive layer with diffusing agents, and (d) a cover film, [0241]
A film construction comprising the following elements immediately
adjacent to each other in the specified order: (a) a diffusing
layer, (b) a light redirecting film, (c) an adhesive layer with
diffusing agents, and (d) a cover film, [0242] A film construction
comprising the following elements adjacent to each other in the
specified order: (a) a diffusing layer, (b) a light redirecting
film, (c) an adhesive layer with diffusing agents, (d) a cover
film, (e) and a window film adhesive, [0243] A film construction
comprising the following elements immediately adjacent to each
other in the specified order: (a) a diffusing layer, (b) a light
redirecting film, (c) an adhesive layer with diffusing agents, (d)
a cover film, (e) and a window film adhesive, [0244] A film
construction comprising the following elements adjacent to each
other in the specified order: (a) a diffusing layer, (b) a light
redirecting film, (c) an adhesive layer with diffusing agents, (d)
a cover film, (e) a window film adhesive, and (f) a liner, [0245] A
film construction comprising the following elements immediately
adjacent to each other in the specified order: (a) a diffusing
layer, (b) a light redirecting film, (c) an adhesive layer with
diffusing agents, (d) a cover film, (e) a window film adhesive, and
(f) a liner, [0246] A film construction comprising the following
elements adjacent to each other in the specified order: (a) a
microreplicated diffuser coating, (b) a light redirecting film, (c)
an adhesive layer with diffusing agents, and (d) a cover film,
[0247] A film construction comprising the following elements
immediately adjacent to each other in the specified order: (a) a
microreplicated diffuser coating, (b) a light redirecting film, (c)
an adhesive layer with diffusing agents, and (d) a cover film,
[0248] A film construction comprising the following elements
adjacent to each other in the specified order: (a) a
microreplicated diffuser coating, (b) a light redirecting film, (c)
an adhesive layer with diffusing agents, (d) a cover film, (e) and
a window film adhesive, [0249] A film construction comprising the
following elements immediately adjacent to each other in the
specified order: (a) a microreplicated diffuser coating, (b) a
light redirecting film, (c) an adhesive layer with diffusing
agents, (d) a cover film, (e) and a window film adhesive, [0250] A
film construction comprising the following elements adjacent to
each other in the specified order: (a) a microreplicated diffuser
coating, (b) a light redirecting film, (c) an adhesive layer with
diffusing agents, (d) a cover film, (e) a window film adhesive, and
(f) a liner, [0251] A film construction comprising the following
elements immediately adjacent to each other in the specified order:
(a) a microreplicated diffuser coating, (b) a light redirecting
film, (c) an adhesive layer with diffusing agents, (d) a cover
film, (e) a window film adhesive, and (f) a liner, [0252] A film
construction comprising the following elements adjacent to each
other in the specified order: (a) a coating with diffusing agents,
(b) a light redirecting film, (c) an adhesive layer with diffusing
agents, and (d) a cover film, [0253] A film construction comprising
the following elements immediately adjacent to each other in the
specified order: (a) a coating with diffusing agents, (b) a light
redirecting film, (c) an adhesive layer with diffusing agents, and
(d) a cover film, [0254] A film construction comprising the
following elements adjacent to each other in the specified order:
(a) a coating with diffusing agents, (b) a light redirecting film,
(c) an adhesive layer with diffusing agents, (d) a cover film, (e)
and a window film adhesive, [0255] A film construction comprising
the following elements immediately adjacent to each other in the
specified order: (a) a coating with diffusing agents, (b) a light
redirecting film, (c) an adhesive layer with diffusing agents, (d)
a cover film, (e) and a window film adhesive, [0256] A film
construction comprising the following elements adjacent to each
other in the specified order: (a) a coating with diffusing agents,
(b) a light redirecting film, (c) an adhesive layer with diffusing
agents, (d) a cover film, (e) a window film adhesive, and (f) a
liner, [0257] A film construction comprising the following elements
immediately adjacent to each other in the specified order: (a) a
coating with diffusing agents, (b) a light redirecting film, (c) an
adhesive layer with diffusing agents, (d) a cover film, (e) a
window film adhesive, and (f) a liner, [0258] A film construction
comprising the following elements adjacent to each other in the
specified order: (a) a light redirecting film with diffusing
agents, (b) an adhesive layer, and (c) a cover film, [0259] A film
construction comprising the following elements immediately adjacent
to each other in the specified order: (a) a light redirecting film
with diffusing agents, (b) an adhesive layer, and (c) a cover film,
[0260] A film construction comprising the following elements
adjacent to each other in the specified order: (a) a light
redirecting film with diffusing agents, (b) an adhesive layer, (c)
a cover film, (d) and a window film adhesive, [0261] A film
construction comprising the following elements immediately adjacent
to each other in the specified order: (a) a light redirecting film
with diffusing agents, (b) an adhesive layer, (c) a cover film, (d)
and a window film adhesive, [0262] A film construction comprising
the following elements adjacent to each other in the specified
order: (a) a light redirecting film with diffusing agents, (b) an
adhesive layer, (c) a cover film, (d) a window film adhesive, and
(e) a liner, [0263] A film construction comprising the following
elements immediately adjacent to each other in the specified order:
(a) a light redirecting film with diffusing agents, (b) an adhesive
layer, (c) a cover film, (d) a window film adhesive, and (e) a
liner, [0264] A film construction comprising the following elements
adjacent to each other in the specified order: (a) a light
redirecting film with diffusing agents, (b) an adhesive layer with
diffusing agents, and (c) a cover film, [0265] A film construction
comprising the following elements immediately adjacent to each
other in the specified order: (a) a light redirecting film with
diffusing agents, (b) an adhesive layer with diffusing agents, and
(c) a cover film, [0266] A film construction comprising the
following elements adjacent to each other in the specified order:
(a) a light redirecting film with diffusing agents, (b) an adhesive
layer with diffusing agents, (c) a cover film, (d) and a window
film adhesive, [0267] A film construction comprising the following
elements immediately adjacent to each other in the specified order:
(a) a light redirecting film with diffusing agents, (b) an adhesive
layer with diffusing agents, (c) a cover film, (d) and a window
film adhesive, [0268] A film construction comprising the following
elements adjacent to each other in the specified order: (a) a light
redirecting film with diffusing agents, (b) an adhesive layer with
diffusing agents, (c) a cover film, (d) a window film adhesive, and
(e) a liner, and [0269] A film construction comprising the
following elements immediately adjacent to each other in the
specified order: (a) a light redirecting film with diffusing
agents, (b) an adhesive layer with diffusing agents, (c) a cover
film, (d) a window film adhesive, and (e) a liner.
[0270] Light Redirecting Films
[0271] The first optical film may be any suitable film that has
high optical transparency in the visible light region of the
spectrum. The first optical film may be a single layer film or a
multilayer film construction. The first optical film has a first
major surface and a second major surface. The first major surface
comprises a microstructured surface. This microstructured surface
comprises an ordered arrangement of a plurality of asymmetrical
multi-peaked microstructured prismatic elements.
[0272] A variety of articles have been developed to redirect
sunlight to provide illumination within rooms. For example, the
following patents and patent applications describe various light
redirecting films and light redirecting microstructures: US Patent
Publication No. 2008/0291541, titled "Light Redirecting Solar
Control Film", filed May 23, 2007 (Padiyath et al.) and pending
U.S. Patent Applications Nos. 61/287,360, titled "Light Redirecting
Constructions" filed Dec. 17, 2009 (Padiyath et al), and
61/287,354, titled "Light Redirecting Film Laminate" filed Dec. 17,
2009 (Padiyath et al.); PCT Application Publication No. WO
2012/134787, titled "Hybrid Light Redirecting and Light Diffusing
Constructions", filed Mar. 12, 2012 (Padiyath et al.), U.S. Pat.
No. 5,551,042, titled "Structured Films and Use Thereof for
Daylight Illumination", issued Aug. 27, 1996 (Lea, et al.), US
Patent Publication No. 2014/0211331, titled "Multiple Sequenced
Daylight Redirecting Layers", filed Mar. 27, 2014 (Padiyath et
al.), PCT application titled "Lighting sheet, lighting panel,
roll-up lighting screen, and method for manufacturing lighting
sheet" published as WO2014147793A1, U.S. Pat. No. 8,040,610 titled
"Light Guiding Film", issued Oct. 18, 2011 (Ko, et al.), U.S. Pat.
No. 8,107,164 titled "Window System and Light Guiding Film
Therein", issued Jan. 31, 2012 (Tsai), U.S. Pat. No. 8,664,521
titled" "Window System and Light Guiding Film Therein", issued Mar.
4, 2014 (Tsai et al.), US Patent Publication No. 2014/0198390,
titled "Dual-sided Daylight Redirecting Film", filed Mar. 27, 2014
(Padiyath, et al.), US Patent Publication No. 2008/0292820, titled
"Light Diffusing Solar Control Film", filed May 23, 2007 (Padiyath,
et al.), U.S. Pat. No. 6,456,437, titled "Optical Sheets Suitable
for Spreading Light", issued Sep. 24, 2002 (Lea, et al.), PCT
application titled "Room-Facing Light Redirecting Film with Reduced
Glare," published as
[0273] WO 2016/064667 and PCT application titled "Sun-Facing Light
Redirecting Film with Reduced Glare," published as WO 2016/064621.
The light redirecting films and light redirecting microstructures
disclosed in the patents and patent applications in this paragraph
are herein incorporated by reference. In general, any light
redirecting film or layer, including those mentioned in this
paragraph, and others known in the art, can be used in the
constructions of this disclosure.
[0274] In certain embodiments, although the design of a given
microstructured prismatic element shows sharp peaks (sharp apex
angles), due to manufacturing effects, the actual manufactured
microstructured prismatic element may have rounded peaks, as can be
seen in FIGS. 14 and 15.
[0275] Diffusive Elements
[0276] While one of the main incentives for using light redirecting
films is energy savings, visual comfort needs to be taken into
account. As shown in FIG. 1, while most of the sunlight is directed
upwards a fraction may go downwards. This downward light can cause
glare for the occupants. Because sunlight is highly collimated with
about 0.5 degree spread and appears as a solar disk, sometimes a
light redirecting film spreads that light vertically to form a
solar column.
[0277] Both the total fraction of downward directed light and
brightness of the solar column contribute to glare (visual
discomfort). The brightness of the solar column depends on its
angular spread. One solution the inventors have found to reduce
glare is to introduce one or more diffuser layers in the optical
path. The diffuser helps to spread out the solar column. In
addition, the diffusive element provides more uniform ceiling
illumination by diffusing the upward directed light. The inventors
have found that the use of the diffuser layer reduces glare and the
visibility of the solar column significantly. The diffuser layer
can also contribute other beneficial properties such as the
reduction (or mitigation) optical artifacts such as moire or color
and the diffusion can also help hide cosmetic defects.
[0278] In some embodiments, diffusion may be accomplished by
creating surface diffusers, bulk diffusers, and/or embedded
diffusers. A diffusive element, also called a diffuser or a
diffusing layer in this disclosure, may be a separate layer or
coating having diffusive properties with respect to visible light
or a surface treatment on a layer of the film constructions of the
present disclosure that provides diffusive properties to the
treated surface (e.g., a surface diffuser). For example, the
diffusive element may be a separate layer (e.g., a bulk diffuser)
that diffuses visible light and that is either coextruded, coated,
or laminated to another layer of the film constructions of the
present disclosure.
[0279] In some embodiments, bulk diffusion is accomplished by
adding a diffusing agent, such as micro beads or nanoparticles to
the coating or layer. In other embodiments, the diffusing agent is
chosen from micro beads having average size from 0.1 microns to 100
microns, from 0.5 microns to 50 microns, 0.7 microns to 20 microns,
and 1 micron to 5 microns.
[0280] A variety of diffusers have been developed and are known in
the art. For example, the following patents and patent applications
describe various type of diffusers: U.S. Patent Publication No.
2014/0104689, titled "Hybrid Light Redirecting and Light Diffusing
Constructions, filed Dec. 5, 2013, (Padiyath, et al.); PCT
Application Publication No. WO 2014/093119, titled "Brightness
Enhancing Film with Embedded Diffuser", filed Dec. 5, 2013, (Boyd
et al.); U.S. Pat. No. 6,288,172, titled "Light Diffusing
Adhesive", issued Sep. 11, 2001 (Goetz, et al.); PCT Application
Publication No. WO 2013/158475, titled "Brightness Enhancement Film
with Substantially Non-imaging Embedded Diffuser", filed Apr. 12,
2013, (Boyd, et al.), US 2015/0293272 (Pham), US 2013/0236697
(Walker), PCT Application Publication No. WO2015/050750 titled
"Microstructured diffuser comprising first microstructured layer
and coating, optical stacks, and method", filed Sep. 24, 2014
(Naismith et al.), U.S. Patent Publication No. US20150293272 titled
"Optical diffusing films and methods of making same", filed Nov.
19, 2013 (Pham, et al.). The diffusers disclosed in the patents and
patent applications in this paragraph are herein incorporated by
reference. In general, any diffuser or diffusive element, including
those mentioned in this paragraph, and others known in the art, can
be used in the constructions of this disclosure.
[0281] One option to combine the effect of a diffuser with a light
redirecting film is to adhere the light redirecting film to the
window and mount the diffuser to an added pane. The present
disclosure presents a solution where the diffuser layer and the
light redirecting film in a single construction.
[0282] In some embodiments, the diffusing properties can lie within
the adhesive, the window film adhesive, or any of the substrates
that may be part of the light redirecting construction. In certain
embodiments, the diffusing properties of any of the elements
mentioned in the preceding sentence may be modified by introducing
surface roughness, bulk diffusion, or using embedded diffusers. In
other embodiments, the diffusing properties
[0283] In certain embodiments, the surface of a layer part of a
light redirecting construction can be treated in such a manner that
the layer diffuses visible light. Surface roughness to create
diffusing properties in a layer can be accomplished by imparting a
pattern on the surface of a layer that increases the angular spread
of input light in a desired manner. Some methods used to impart
such a pattern include embossing, replication, and coating.
[0284] In other embodiments, bulk diffusion can be accomplished by
adding one or more diffusing agents to the window film adhesive.
Diffusing agents can comprise particles or beads. Examples of
diffusing agents include: polymeric or inorganic particles,
spherical beads, and/or voids included in a layer.
[0285] As mentioned above, in some embodiments, the diffusive
element comprises inorganic oxide nanoparticles, such as zirconia
or silica nanoparticles. The size of the nanoparticles is chosen to
avoid significant visible light back-scattering. In some
embodiments, it may be desirable to employ a mixture of inorganic
oxide particle types to obtain a specific optical or material
property and/or to lower total composition cost.
[0286] In other embodiments, the diffusive element comprises
surface modified colloidal nanoparticles, which can be inorganic
oxide particles having a (e.g. unassociated) primary particle size
or associated particle size of at least 1 nm or at least 5 nm. The
primary or associated particle size is generally less than 100 nm,
75 nm, or 50 nm. Typically the primary or associated particle size
is less than 40 nm, 30 nm, or 20 nm. It is preferred that the
nanoparticles be unassociated. The nanoparticles measurements can
be based on transmission electron miscroscopy (TEM). Surface
modified colloidal nanoparticles can be substantially fully
condensed.
[0287] Fully condensed nanoparticles (with the exception of silica)
typically have a degree of crystallinity (measured as isolated
metal oxide particles) greater than 55%, preferably greater than
60%, and more preferably greater than 70%. For example, the degree
of crystallinity can range up to about 86% or greater. The degree
of crystallinity can be determined by X-ray diffraction techniques.
Condensed crystalline (e.g. zirconia) nanoparticles have a high
refractive index whereas amorphous nanoparticles typically have a
lower refractive index.
[0288] In other embodiments, the diffusive element comprises
embedded particles or beads. Particles typically have an average
size that is greater than about 0.25 microns (250 nanometers), or
greater than about 0.5 microns, or greater than about 0.75 microns,
or greater than about 1 micron, or greater than about 1.25 microns,
or greater than about 1.5 microns, or greater than about 1.75
microns, or greater than about 2 microns. Smaller particles are
typical for diffusive elements that are relatively thin.
[0289] However, for embodiments wherein the diffusive element is
thicker, the particles may have an average size up to 5 microns or
10 microns. The concentration of particles may range from at least
1 or 2 wt-% to about 5, 6, 7, 8, 9, or 10 wt-% or greater.
[0290] The diffusive elements disclosed in PCT Application
Publication No. WO 2015/020750 are incorporated herein by
reference.
[0291] In yet other embodiments, a substrate or a layer part of a
light redirecting construction can contain embedded diffusers. In
one embodiment, an embedded diffuser layer can be formed in between
the light redirecting layer and the substrate. This layer may
consist of a matrix with diffusing agents. Alternatively the layer
may be a surface diffuser layer consisting of a material with a
refractive index sufficiently different from the light redirecting
layer to obtain a desired level of diffusion. In other embodiments,
various types of diffusers may also be used in combination.
[0292] Diffusing agents (such as beads or particles) can be
incorporated into a diffuser layer (e.g., a diffuser coating), a
light redirecting substrate, the microstructured prismatic element,
the adhesive layer, the cover film, or the window film adhesive,
which correspond to layers 1,2,3,4,5 or 6 as shown in FIG. 30.
[0293] The beads (or particles) incorporated into a diffuser layer
or the adhesive layer (layers 1 or 4 in FIG. 30) can be in the form
of a thin film or a coating, such as a hardcoat or a layer
comprising an adhesive. However, the diffuser layer can also be
laminated to the light redirecting substrate. A diffusing coating
can be prepared by adding beads (or particles), such as described
in U.S. Pat. Nos. 6,778,240 and 7,190,525, which are incorporated
herein by reference. In one embodiment, clear beads with
appropriate refractive index, for example PMMA beads are used in an
acrylate adhesive. These Index-matched beads incorporated into
diffuser layer or the adhesive layer can modify the surface texture
resulting in a surface diffuser. This thin layer can be described a
"surface" diffuser. [0294] Beads incorporated into the bulk of the
light redirecting substrate, the microstructured prismatic element,
the cover film, or the window film adhesive (layers 2,3,5, or 6 in
FIG. 30) which have different refractive index can be scattering.
Organic beads; for example polystyrene or inorganic particles, for
example, TiO2 can be used. The different in refractive index in the
bulk of the film can be described as a "bulk" diffuser. In general,
bulk diffusers have lower light transmission than surface diffusers
due to multiple scatterings and back-scattering of light. [0295] In
another embodiment, comprises fabricating a microtextured layer on
the plano surface of light redirecting substrate (layer 2 of FIG.
29). In this configuration, element 1 represents the microtextured
surface. This may be done, for example, by creating microstructures
on the surface. Alternatively, element 1 can comprise a
microtextured film that is laminated to element 2.
[0296] Cover Film
[0297] The film constructions of the present disclosure also
comprise a second film, or cover film. In some embodiments, the
cover film is an optical film. In general, the cover film has a
first major surface and a second major surface. Typically, the
second major surface of the second optical film is coated with an
adhesive that makes contact with and is bonded to at least some of
the microstructures on the surface of the first optical film.
[0298] The second film may be the made of the same material or
materials as the first optical film, or it may be different. In
some embodiments, the second film protects the microstructured
surface and prevents the microstructured prismatic elements from
becoming damaged, dirty or otherwise rendered incapable of
redirecting light.
[0299] Besides being the protective layer for the microstructured
surface, the second film can also provide additional functionality
to the light redirecting laminate. For example, the second optical
film can be a multilayer film that can reflect infrared light. In
this way the light redirecting film construction can also help to
keep the undesirable infrared light (heat) out of the building
while allowing the desirable visible light into the building.
Examples of suitable multilayer films useful as the cover film,
include those disclosed, for example, in U.S. Pat. Nos. 6,049,419,
5,223,465, 5,882,774, 6,049,419, RE 34,605, 5,579,162 and
5,360,659, which films are incorporated herein by reference as
possible cover films useful in the film constructions of the
present invention.
[0300] In some embodiments, the cover film is a multilayer film in
which the alternating polymeric layers cooperate to reflect
infrared light. In some embodiments, at least one of the polymeric
layers is a birefringent polymer layer.
[0301] In some embodiments, when the first major surface of the
second optical film is exposed to the inside of the room, it may be
desirable to have additional coatings on the exposed major surface
of the cover film. For example, the surface may contain a
protective coating such as a hardcoat to prevent the surface from
scratches and marks as well as to protect the surface from damage
from surface cleaners, or to make the surface graffiti-resistant or
easier to clean. Examples of suitable coatings include, for
example, hardcoats, anti-scratch coatings, low surface energy
coatings or easy clean coatings.
[0302] Typically, the second optical film or second multilayer
optical film, is prepared from polymeric materials that permit the
film to be optically clear. Examples of suitable polymeric
materials include, for example, polyolefins such as polyethylene
and polypropylene, polyvinyl chloride, polyesters such as
polyethylene terephthalate, polyamides, polyurethanes, cellulose
acetate, ethyl cellulose, polyacrylates, polycarbonates, silicones,
and combinations or blends thereof.
[0303] The optical film may contain other components besides the
polymeric material, such as fillers, stabilizers, antioxidants,
plasticizers and the like. In some embodiments, the optical film
may comprise a stabilizer such as a UV absorber (UVA).
[0304] Adhesives
[0305] Typically, the second major surface of the second film
(cover film) contacts the adhesive layer, which in turn contacts at
least the tops of the refractive microstructured prismatic
elements. Bonding occurs at the areas of contact between the second
film and the adhesive. Similarly, there is bonding between the tops
of the microstructured prismatic elements and the adhesive.
[0306] In certain embodiments, this bonding may take a variety of
forms useful for laminating together two polymeric units, including
adhesive bonding, heat lamination, ultrasonic welding and the like.
For example, in one embodiment, the second film could be heated to
soften the film and the film contacted to the microstructured
surface of the first optical film. The heated film, upon cooling,
forms bonds to the contacted portions of the micro structured layer
of the first optical film. Similarly, the second film could be dry
laminated to the microstructured surface of the first optical film
and then heat, either directly or indirectly, could be applied to
produce the laminated article. Alternatively, an ultrasonic welder
could be applied to the dry laminate construction. However,
typically, adhesive bonding is used. When adhesive bonding is used,
either a heat activated adhesive or a pressure sensitive adhesive
can be used. Generally, pressure sensitive adhesives are used,
especially the optically clear pressure sensitive adhesives.
[0307] To effect the adhesive bonding, the adhesive may be applied
either to the microstructured surface of the first optical film, or
to the second major surface of the second optical film. Typically,
the adhesive is applied to the second major surface of the second
optical film. The applied adhesive coating may be continuous or
discontinuous.
[0308] The adhesive coating may be applied through any of a variety
of coating techniques including knife coating, roll coating,
gravure coating, rod coating, curtain coating, air knife coating,
or a printing technique such as screen printing or inkjet printing.
The adhesive may be applied as aqueous or solvent based (e.g.,
solution, dispersion, suspension), or 100% solids composition. If
aqueous or solvent-based adhesive compositions are used, typically,
the coating is dried prior to lamination by air drying or at
elevated temperatures using, for example, an oven such as a forced
air oven. The adhesive coated cover film can then be laminated to
the microstructured surface of the first optical film. The
lamination process should be well controlled to provide uniform and
even contact on the tips of the microstructured prisms described
above.
[0309] In certain embodiments, the adhesives used to laminate the
two films in constructions according to this disclosure, have the
following characteristics:
[0310] a) the adhesive (after drying) flows into the
microstructured prismatic elements under suitable conditions, for
example those used to laminate the two films. Suitable conditions,
such as lamination, typically include heat, pressure, and, if
performed in roll-to-roll operations, a certain line speed. The
flow properties and thickness of the adhesive relative to the
microstructured prismatic elements may be adjusted as needed.
Adhesive properties that could influence flow include molecular
weight, cross link density, and additives, such as
plasticizers;
[0311] b) the adhesive is resistant to "creep" under the conditions
used to store, apply, and use the product; and
[0312] c) the adhesive is durable under UV exposure and thermal
conditions encountered. In some embodiments, UV stabilizers, such
as a UV absorber (UVA) or hindered amine light stabilizer (HALS),
may be added to the adhesive.
[0313] In certain embodiments, the adhesive in the adhesive layer
is chosen from a pressure sensitive adhesive, a thermoset adhesive,
hot melt adhesive, and a UV-curable adhesive.
[0314] Suitable adhesives can be or include any optical adhesive
that may be desirable in an application. Exemplary optical
adhesives include pressure sensitive adhesives (PSAs),
heat-sensitive adhesives, solvent-volatile adhesives, and
UV-curable adhesives such as UV-curable optical adhesives available
from Norland Products, Inc. Exemplary PSAs include those based on
natural rubbers, synthetic rubbers, styrene block copolymers,
(meth)acrylic block copolymers, polyvinyl ethers, polyolefins, and
poly(meth)acrylates or silicones.
[0315] As used herein, (meth)acrylic (or acrylate) refers to both
acrylic and methacrylic species. Other exemplary PSAs include
(meth)acrylates, rubbers, thermoplastic elastomers, silicones,
urethanes, and combinations thereof. In some cases, the PSA is
based on a (meth)acrylic PSA or at least one poly(meth)acrylate.
Exemplary silicone PSAs include a polymer or gum and an optional
tackifying resin. Other exemplary silicone PSAs include a
polydiorganosiloxane polyoxamide and an optional tackifier.
[0316] In some cases, an optical adhesive layer can be or include a
structural adhesive. Generally, useful structural adhesives contain
reactive materials that cure to form a strong adhesive bond. The
structural adhesive may cure spontaneously upon mixing (such as a 2
part epoxy adhesive) or upon exposure to air (such as a
cyanoacrylate adhesive) or curing may be effected by the
application of heat or radiation (such as UV light). Examples of
suitable structural adhesives include epoxies, acrylates,
cyanoacrylates, urethanes, and the like.
[0317] Other exemplary pressure sensitive adhesives for use in the
articles of the present disclosure include crosslinked tackified
acrylic pressure-sensitive adhesives. Other pressure sensitive
adhesives such as blends of natural or synthetic rubber and resin,
silicone or other polymer systems, with or without additives can be
used in the film constructions of this disclosure.
[0318] Acrylic Acid and Meth(acrylic) Acid Esters: The acrylic
esters are present at ranges of from about 65 to about 99 parts by
weight, for example from about 78 to about 98 parts by weight, and
in some embodiments from about 90 to about 98 parts by weight.
Useful acrylic esters include at least one monomer selected from
the group consisting of a first monofunctional acrylate or
methacrylate ester of a non-tertiary alkyl alcohol, the alkyl group
of which comprises from 4 to about 12 carbon atoms, and mixtures
thereof. Such acrylates or methacrylate esters generally have, as
homopolymers, glass transition temperatures below about -25.degree.
C. A higher amount of this monomer relative to the other comonomers
affords the PSA higher tack at low temperatures.
[0319] Examples of acrylate or methacrylate ester monomers include,
but are not limited to, those selected from the group consisting of
n-butyl acrylate (BA), n-butyl methacrylate, isobutyl acrylate,
2-methyl butyl acrylate, 2-ethylhexyl acrilate, n-octyl acrylate,
isooctyl acrylate (IOA), isooctyl methacrylate, isononyl acrylate,
isodecyl acrylate, and mixtures thereof.
[0320] In some embodiments, the acrylates include those selected
from the group consisting of isooctyl acrylate, n-butyl acrylate,
2-methyl butyl acrylate, 2-ethylhexyl acrylate, and mixtures
thereof.
[0321] Polar Monomers: Low levels of (typically about 1 to about 10
parts by weight) of a polar monomer such as a carboxylic acid can
be used to increase the cohesive strength of the pressure-sensitive
adhesive. At higher levels, these polar monomers tend to diminish
tack, increase glass transition temperature and decrease low
temperature performance.
[0322] Useful copolymerizable acidic monomers include, but are not
limited to, those selected from the group consisting of
ethylenically unsaturated carboxylic acids, ethylenically
unsaturated sulfonic acids, and ethylenically unsaturated
phosphonic acids. Examples of such monomers include those selected
from the group consisting of acrylic acid (AA), methacrylic acid,
itaconic acid, fumaric acid, crotonic acid, citraconic acid, maleic
acid, beta-carboxyethyl acrylate, sulfoethyl methacrylate, and the
like, and mixtures thereof.
[0323] Other useful copolymerizable monomers include, but are not
limited to, (meth)acrylamides, N,N-dialkyl substituted
(meth)acrylamides, N-vinyl lactams, and
N,N-dialkylaminoalkyl(meth)acrylates. Illustrative examples
include, but are not limited to, those selected from the group
consisting of N,N-dimethyl acrylamide, N,N-dimethyl methacrylamide,
N,N-diethyl acrylamide, N,N-diethyl methacrylamide,
N,N-dimethylaminoethyl methacrylate, N,N-dimethylaminopropyl
methacrylate, N,N-dimethylaminoethyl acrylate,
N,N-dimethylaminopropyl acrylate, N-vinyl pyrrolidone, N-vinyl
caprolactam, and the like, and mixtures thereof.
[0324] Non-polar Ethylenically Unsaturated Monomers: The non-polar
ethylenically unsaturated monomer is a monomer whose homopolymer
has a solubility parameter as measured by the Fedors method (see
Polymer Handbook, Bandrup and Immergut) of not greater than 10.50
and a Tg greater than 15.degree. C. The non-polar nature of this
monomer tends to improve the low energy surface adhesion of the
adhesive. These non-polar ethylenically unsaturated monomers are
selected from the group consisting of alkyl(meth)acrylates,
N-alkyl(meth)acrylamides, and combinations thereof. Illustrative
examples include, but are not limited to, 3,3,5-trimethylcyclohexyl
acrylate, 3,3,5-trimethylcyclohexyl methacrylate, cyclohexyl
acrylate, cyclohexyl methacrylate, isobornyl acrylate, isobornyl
methacrylate, N-octyl acrylamide, N-octyl methacrylamide or
combinations thereof. Optionally, from 0 to 25 parts by weight of a
non-polar ethylenically unsaturated monomer may be added.
[0325] Tackifiers: In some embodiments, tackifiers are added to the
adhesive and can include terpene phenolics, rosins, rosin esters,
esters of hydrogenated rosins, synthetic hydrocarbon resins and
combinations thereof. These provide good bonding characteristics on
low energy surfaces. Hydrogenated rosin esters and hydrogenated C9
aromatic resins are useful tackifiers in some embodiments, because
of performance advantages that include high levels of "tack",
outdoor durability, oxidation resistance, and limited interference
in post crosslinking of acrylic PSAs.
[0326] Tackifiers may be added at a level of about 1 to about 65
parts per 100 parts of the monofunctional acrylate or methacrylate
ester of a non-tertiary alkyl alcohol, the polar monomer, and the
nonpolar ethylenically unsaturated monomer to achieve desired
"tack". Preferably, the tackifier has a softening point of about 65
to about 100.degree. C. However, the addition of tackifiers can
reduce shear or cohesive strength and raise the Tg of the acrylic
PSA, which is undesirable for cold temperature performance.
[0327] Crosslinkers: In one embodiment, crosslinkers are added to
the adhesive. In order to increase the shear or cohesive strength
of acrylic pressure-sensitive adhesives, a crosslinking additive
may be incorporated into the PSA. Two main types of crosslinking
additives are commonly used. The first crosslinking additive is a
thermal crosslinking additive such as a multifunctional aziridine.
One example is 1,1'-(1,3-phenylene
dicarbonyl)-bis-(2-methylaziridine) (CAS No. 7652-64-4), referred
to herein as "bisamide". Such chemical crosslinkers can be added
into solvent-based PSAs after polymerization and activated by heat
during oven drying of the coated adhesive.
[0328] In another embodiment, chemical crosslinkers that rely upon
free radicals to carry out the crosslinking reaction may be
employed. Reagents such as, for example, peroxides serve as a
source of free radicals. When heated sufficiently, these precursors
will generate free radicals, which bring about a crosslinking
reaction of the polymer. A common free radical generating reagent
is benzoyl peroxide. Free radical generators are required only in
small quantities, but generally require higher temperatures to
complete the crosslinking reaction than those required for the
bisamide reagent.
[0329] In certain embodiments, the adhesive can be a heat-activated
adhesive, such as hot-melt adhesive. Heat-activated adhesives are
non-tacky at room temperature but become tacky and capable of
bonding to a substrate at elevated temperatures. These adhesives
usually have a glass transition temperature (Tg) or melting point
(Tm) above room temperature. When the temperature is increased
above the Tg or Tm, the storage modulus usually decreases and the
adhesive becomes tacky.
[0330] In some embodiments, the adhesive diffuses visible light. As
mentioned before, diffusion can be accomplished by creating surface
diffusers, bulk diffusers, and embedded diffusers.
[0331] Ultraviolet Absorbers
[0332] In certain embodiments, the adhesives and other layers or
elements of the film constructions of the present disclosure may
contain ultraviolet absorbers. In certain preferred embodiments,
the UV absorbers are incorporated in the window film PSA which is
the first layer of the LRF exposed to sunlight, thereby protecting
the other layers of the redirecting film assembly. Ultraviolet
absorbers function by preferentially absorbing ultraviolet
radiation and dissipating it as thermal energy. Suitable UVAs may
include: benzophenones (hydroxybenzophenones, e.g., Cyasorb 531
(Cytec)), benzotriazoles (hydroxyphenylbenzotriazoles, e.g.,
Cyasorb 5411, Tinuvin 329 (Ciba Geigy)), triazines
(hydroxyphenyltriazines, e.g., Cyasorb 1164), oxanilides, (e.g.,
Sanuvor VSU (Clariant)) cyanoacrylates (e.g., Uvinol 3039 (BASF)),
or benzoxazinones. Suitable benzophenones include, CYASORB UV-9
(2-hydroxy-4-methoxybenzophenone, CHIMASSORB 81 (or CYASORB UV 531)
(2 hyroxy-4 octyloxybenzophenone). Suitable benzotriazole UVAs
include compounds available from Ciba, Tarrytown, N.Y. as TINUVIN
P, 213, 234, 326, 327, 328, 405 and 571, and CYASORB UV 5411 and
CYASORB UV 237. Other suitable UVAs include CYASORB UV 1164
(2-[4,6-bis(2,4-dimethylphenyl)-1,3,5-triazin-2yl]-5(oxctyloxy)
phenol (an exemplary triazine) and CYASORB 3638 (an exemplary
benzoxiazine).
[0333] Hindered amine light stabilizers (HALS) are efficient
stabilizers against light-induced degradation of most polymers.
HALS do not generally absorb UV radiation, but act to inhibit
degradation of the polymer. HALS typically include tetra alkyl
piperidines, such as 2,2,6,6-tetramethyl-4-piperidinamine and
2,2,6,6-tetramethyl-4-piperidinol. Other suitable HALS include
compounds available from Ciba, Tarrytown, N.Y. as TINUVIN 123, 144,
and 292.
[0334] The UVAs and HALS disclosed explicitly here are intended to
be examples of materials corresponding to each of these two
categories of additives. The present inventors contemplate that
other materials not disclosed here but known to those skilled in
the art for their properties as UV absorbers or hindered amine
light stabilizers can be used in the constructions of this
disclosure.
[0335] Light Redirecting Film Configurations
Room-Facing Configurations
[0336] A room-facing light redirecting assembly is shown in FIG.
29(a). In this embodiment, the redirecting film with the structures
oriented towards the room is bonded to the cover film. The cover
film may include diffusing properties depending on the optical
performance of the light redirecting microstructure. The diffuser
may be surface, bulk, or embedded diffuser. Diffusion may also be
included in the adhesive. The assembly may be mounted to a window
or glazing using window film adhesive.
Sun-Facing Configurations
[0337] A sun-facing light redirecting configuration is shown in
FIG. 29(b). In that embodiment, the microstructured prismatic
elements are oriented towards the incoming sunlight. In this
embodiment, the microstructure substrate may also have diffusing
properties integrated into it. In certain embodiments, diffusive
properties can be achieved by coating a surface diffuser on the
substrate side opposing the microstructured prismatic elements.
This substrate could also include bulk diffusion properties. This
substrate may have a window film adhesive coated on the opposing
face to attach to a glazing.
[0338] In some embodiments, the present disclosure is directed to a
window comprising any of the films described above.
[0339] In certain embodiments, such as in the above room-facing and
sun-facing constructions, diffusion may be incorporated in the
substrates and/or adhesives. Diffusers may be surface, bulk, or
embedded diffusers.
[0340] In some embodiments, the window film adhesive diffuses
visible light. As mentioned before, diffusion can be accomplished
by creating surface diffusers, bulk diffusers, and embedded
diffusers.
[0341] In other embodiments, the shape of the construction is
circular or ellipsoidal shape and the edge of the construction is
sealed all around. As mentioned before, the sealing can occur: by
the use of a sealing agent, by the adhesive layer as described
above, by using an edge sealing tape, or by using pressure,
temperature, or some combination of both, including the use of a
hot knife.
[0342] In yet other embodiments constructions as described in the
preceding paragraph may have a diffuser (bulk, surface, or
embedded) on what originally was a see-through region.
[0343] Edge Sealing
[0344] One potential limitation of tip-bonded constructions is that
they may not be fully sealed at the edges. The microstructures
described above may be linear. Bonding such structures at the tips
to the cover film leaves air channels in the construction. Under
certain circumstance, these air channels can act as micro
capillaries. Water introduced at the edges either during wet
lamination during installation or condensation may be drawn into
the air channels immersing the microstructures. Such edge ingress
degrades optical performance and may be visually unacceptable.
[0345] To overcome this, in certain embodiments, tip-bonded
constructions may be sealed at the edges to prevent ingress of
contaminants such as moisture and dirt. In those embodiments, one
option to seal at least a portion of the edge is for the adhesive
layer to fill the space between at least two immediately adjacent
microstructured prismatic elements. In other embodiments, the
entire edge can be sealed in this manner if the adhesive fills the
space between the microstructured prismatic elements near the
edge.
[0346] In some embodiments, the construction has a rectangular or
square shape and the edge of one or more sides, up to all four
sides, is sealed. In certain embodiments, the sealing can occur: by
the use of a sealing agent, by the use of an adhesive layer on the
edge of the film constructions, by using an edge sealing tape,
caulk, thick PSAs, curable formulations (e.g. super glue), or by
using pressure, temperature, or some combination of both, including
the use of a hot knife. A sealing agent would typically be a liquid
adhesive that is applied after the film construction is cut. For UV
stability, acrylate or silicone adhesives would be preferred.
EXAMPLES
[0347] These examples are merely for illustrative purposes only and
not meant to be limiting on the scope of the appended claims. All
parts, percentages, ratios, etc., in the examples and the rest of
the specification are by weight unless otherwise indicated.
TABLE-US-00001 TABLE 1 Materials. % Component Supplier Description
Solids Polyacrylate PSA 3M Company Terpolymer of isooctyl acrylate
(50%), ethyl acrylate 21.2 (St. Paul MN) (40%), and acrylic acid
(10%) having an intrinsic viscosity of 1.9. Uvacure 1500 Cytec
Industries Cycloaliphatic Diepoxide 100 (Woodland Park NJ) DEP
Thirumalai Chemicals Diethyl phthalate 100 (Mumbai, India) Toluene
Aldrich Chemical Solvent 0 (Milwaukee WI) Methanol Aldrich Chemical
Solvent 0 (Milwaukee WI) Ethyl Acetate Aldrich Chemical Solvent 0
(Milwaukee WI) Uvacure 1600 Cytec Industries Diaryl Iodonium
Hexafluoroantimonate Salt, Cationic 100 (Woodland Park NJ)
Photoinitiator Additol ITX Cytec Industries Isopropylthioxanthone
100 (Woodland Park NJ) MX300 Soken Chemical (Japan) Crosslinked
poly(methyl methacrylate) spherical beads. 100 The beads have a
nominal diameter of 3 microns. PHOTOMER 6210 IGM Resins Charlotte,
Aliphatic urethane diacrylate (R1) NC SR238 (R2) Sartomer Americas
Hexanediol diacrylate Exton, PA CN2920 (R3) Sartomer Americas
Aliphatic urethane acrylate oligomer Exton, PA SR9003 (R4) Sartomer
Americas Propoxylated neopentyl glycol diacrylate Exton, PA SR351
(R5) Sartomer Americas Trimethylolpropane triacrylate Exton, PA
RHOPLEX 3208 Dow Chemical Acrylic Primer (AP1) Company, Midland, MI
IRGACURE 4265 BASF Corp. Florham Photoinitiator (PI2) Park, NJ TPO
Photoinitiator
Microstructured Optical Films Used in the Examples:
[0348] Film A is a microstructured film made according to the
process described in U.S. Pat. No. 5,763,049, incorporated herein
by reference, using a master tool produced according to the process
described in US2009/0041553, incorporated herein by reference. The
microstructured prismatic elements are aligned linearly in the
down-web (machine direction) and are shaped in cross-section as
shown in FIG. 6. The plano side of the polyester substrate is
primed to promote adhesion.
[0349] Film B is a microstructured film made according to the
process described in U.S. Pat. No. 5,763,049 using a master tool
produced according to the process described in US2009/0041553. The
microstructured prismatic elements are aligned linearly in the
down-web (machine direction) and are shaped in cross-section as
shown in FIG. 7. The plano side of the polyester substrate is
primed to promote adhesion.
[0350] Film C is a microstructured film made according to the
process described in U.S. Pat. No. 5,763,049 using a master tool
produced according to the process described in US2009/0041553. The
microstructured prismatic elements are aligned linearly in the
down-web (machine direction) and are shaped in cross-section as
shown in FIG. 8. The plano side of the polyester substrate is
primed to promote adhesion.
[0351] Film D is a microstructured film made according to the
process described in U.S. Pat. No. 5,763,049 using a master tool
produced according to the process described in US2009/0041553. The
microstructured prismatic elements are aligned linearly in the
down-web (machine direction) and are shaped in cross-section as
shown in FIG. 9. The plano side of the polyester substrate is
primed to promote adhesion.
[0352] Film E (prophetic) is a microstructured film that can be
made according to the process described in U.S. Pat. No. 5,763,049
using a master tool produced according to the process described in
US2009/0041553. The microstructured prismatic elements are shaped
in cross-section as shown in FIG. 23, as described in U.S. patent
application 62/094,626, filed 19 Dec. 2014, which is incorporated
herein by reference. The plano side of the polyester substrate is
primed to promote adhesion.
[0353] Film F (prophetic) is a microstructured film that can be
made according to the process described in U.S. Pat. No. 5,763,049
using a master tool produced according to the process described in
US2009/0041553. The microstructured prismatic elements are shaped
in cross-section as shown in FIG. 24, as described in U.S. patent
application 62/094,626, filed 19 Dec. 2014. The plano side of the
polyester substrate is primed to promote adhesion.
[0354] Film G (prophetic) is a microstructured film that can be
made according to the process described in U.S. Pat. No. 5,763,049
The microstructured prismatic elements are shaped in cross-section
as shown in FIG. 25, as described in U.S. patent application
62/094,626, filed 19 Dec. 2014. The plano side of the polyester
substrate is primed to promote adhesion.
Fabrication of a Cover Film Having a Microstructured Diffusing
Layer
[0355] A microreplicated diffusing layer was applied to a 2 mil PET
substrate as described in U.S. Pat. No. 8,657,472, which is
incorporated herein by reference in its entirety. The diffusing
layer was fabricated from a resin comprising 60 wt % R1, 20 wt %
R2, and 20 wt % R5. To this resin mixture, 0.5 wt % TPO
photoinitiator was added based on the combined resin weight. The
diffusing layer was applied by coating the substrate with the
resin, contacting a microstructured tool with the resin, and curing
the resin while in contact with the tool using a UV lamp. The
resulting cover film had a thickness of 57.6 microns, the visible
light transmission was 93.3%, the haze was 33.1%, and the clarity
was 15.5%.
Light Redirecting Microstructured Prismatic Film B
[0356] The supporting substrate was a 2-mil biaxially-oriented PET
film having an adhesion promoting primer coating comprising AP1
applied to both sides. The replicating resing comprised 60 wt %
Photomer 6010, 20 wt % SR602, 4 wt % SR601, 8 wt % SR351, 8 wt %
Etermer 201. Irgacture 4265 was added as photoinitiator at 0.5 wt %
of the total resin weight. The replicating resin was applied to the
PET substrate in a manner and rate such that the resin was evenly
distributed across the region to be replicated. Replication of the
resin was conducted at 30 feet per minute (fpm) on a tool heated to
125.degree. F. The tool, having the same but complimentary shape as
the desired daylight redirecting structure, had been previously
fabricated using a diamond-turning process. The desired periodic
structure comprised two peaks and four facets per period with one
facet per side of the function.
[0357] The resulting light redirecting prismatic structure is
described in FIG. 7. Radiation from a Fusion "D" lamp operating at
600 W/in was transmitted through the film to cure the resin while
in contact with the tool. The replicated Daylight Redirection
Microstructured Template Film (replicated resin on PET substrate)
was then removed from the tool and wound into a roll in preparation
for further processing.
Light Redirecting Microstructured Prismatic Film A
[0358] The supporting substrate used was a 2-mil biaxially-oriented
PET film having an adhesion promoting primer coating comprising AP1
applied to both sides. The replicating resin was a 75/25 blend of
R1 and R2 with 0.5% photoinitator PI2. The replicating resin was
applied to the PET substrate in a manner and rate such that the
resin was evenly distributed across the region to be replicated.
Replication of the resin was conducted at 30 fpm on a tool heated
to 125.degree. F. The tool, having the same but complimentary shape
as the desired daylight redirecting structure, had been previously
fabricated using a diamond-turning process. The desired periodic
structure comprised two peaks and four facets per period with one
facet per side of the function.
[0359] The resulting daylight redirecting film is further described
in Example No. 2 of U.S. provisional application No. 62/066,302
titled "Sun-Facing Light Redirecting Film with Reduced Glare,"
filed on Oct. 20, 2014. Diffuser Films (WO20164621A1) which is
hereby incorporated herein by reference in its entirety. Radiation
from a Fusion "D" lamp operating at 600 W/in was transmitted
through the film to cure the resin while in contact with the tool.
The replicated Daylight Redirection Microstructured Template Film
(replicated resin on PET substrate) was then removed from the tool
and wound into a roll in preparation for further processing.
Method of Making a Daylight Redirecting Film Assembly
Adhesive Solution 1 (Containing No Diffusion Beads):
[0360] An adhesive solution was prepared by mixing the components
in Table 2. The adhesive solutions consisted of 11% solids.
TABLE-US-00002 TABLE 2 Adhesive formulation. Component Weight (Kg)
Ethyl Acetate 57.18 Toluene 19.68 Methanol 14.09 Polyacrylate PSA
solution 46.32 Uvacure 1500 4.545 Uvacure 1600 0.636 Additol ITX
0.0182 DEP 0.755
[0361] This adhesive solution represents a solvent based adhesive
that upon drying may be cured by exposure to actinic radiation to
form an interpenetrating network (IPN). The composition of the
adhesive on a dry basis is provided in Table 3.
TABLE-US-00003 TABLE 3 Adhesive formulation in weight percent.
Component Weight (%) Polyacrylate PSA 62.3% Uvacure 1500 28.8%
Uvacure 1600 4.03% Additol ITX 0.115% DEP 4.78%
Adhesive Solution 2 (Containing 5 wt % Diffusion Beads):
[0362] An adhesive solution was prepared by mixing the components
shown in Table 4. The adhesive solution was 11% solids.
TABLE-US-00004 TABLE 4 Adhesive formulation. Component Weight (Kg)
Ethyl Acetate 70.55 Toluene 19.68 Methanol 14.09 Polyacrylate PSA
solution 46.32 Uvacure 1500 4.545 Uvacure 1600 0.636 Additol ITX
0.0182 DEP 0.755 MX300 0.827
[0363] This adhesive solution represents a solvent based adhesive
that upon drying may be cured by exposure to actinic radiation to
form an interpenetrating network (IPN). The composition of the
adhesive on a dry basis is provided in Table 5.
TABLE-US-00005 TABLE 5 Adhesive formulation in weight percent.
Component Weight (%) Polyacrylate PSA 59.1% Uvacure 1500 27.4%
Uvacure 1600 3.83% Additol ITX 0.110% DEP 4.55% MX300 4.98%
Adhesive Solution 3 (Containing 9.5 wt % Diffusion Beads):
[0364] An adhesive solution was prepared by mixing the components
shown in Table 6. The adhesive solution was 11% solids.
TABLE-US-00006 TABLE 6 Adhesive formulation. Component Weight (Kg)
Ethyl Acetate 70.55 Toluene 19.68 Methanol 14.09 Polyacrylate PSA
solution 46.32 Uvacure 1500 4.545 Uvacure 1600 0.636 Additol ITX
0.0182 DEP 0.755 MX300 1.655
[0365] This adhesive solution represents a solvent based adhesive
that upon drying may be cured by exposure to actinic radiation to
form an interpenetrating network (IPN). The composition of the
adhesive on a dry basis is provided in Table 7.
TABLE-US-00007 TABLE 7 Adhesive formulation in weight percent.
Component Weight (%) Polyacrylate PSA 56.34% Uvacure 1500 26.08%
Uvacure 1600 3.65% Additol ITX 0.10% DEP 4.33% MX300 9.49%
Coating and Lamination Process for Making a Daylight Redirecting
Film Assembly
Example 1
[0366] Adhesive solution 1 prepared above was coated onto the plano
side of a 50 micron (2 mil) PET cover film which was primed on both
plano sides. The adhesive solution was coated on the cover film
using a slot-type die at a width of 8 in (20.32 cm) and a web speed
of 25 ft/min (7.62 m/min). The adhesive solution was delivered
using a gear driven pump at specified flow rates to provide
coatings of desired thickness. Samples with dry adhesive coating
thickness of 3, 4, 6, and 8 micron were produced. Residual solvent
was removed from the coated film in a convection oven maintained at
a temperature of 150.degree. F. (65.6.degree. C.); the oven length
was 30 ft (9.14 m).
[0367] Microstructured film B was conveyed to a lamination station
and laminated to the adhesive side of the PET cover film with the
microstructured prismatic element side of the film in direct
contact with the adhesive coating. The laminator was configured
with a rubber roll (Shore A Durometer of 68) nipped against a steel
roll; the nip pressure was maintained at approximately 60 psi.
[0368] The laminate was conveyed to a UV curing station, where it
was exposed to actinic radiation. The radiation source was
positioned so that the adhesive was irradiated through the film
comprising the microstructured prismatic elements. The curing
station was comprised of a Fusion F600 (Fusion UV Systems,
Gaithersburg Md.) and a temperature controlled steel backup roll.
The Fusion UV source was configured with a D Bulb and an aluminum
reflector with power setting range of 60-100%. The results are
provided in FIGS. 14-17.
Example 2
[0369] Adhesive solution 1 was coated using a slot-type die onto
the plano side of a 35.5 micron thick (1.4 mil) PET cover film
which was primed on both plano sides. The adhesive solution was
delivered using a gear driven pump at specified flow rates to
provide coatings of desired thickness. Samples with dry adhesive
coating thickness of 3.0 micron, 3.4 micron and 4.5 micron were
produced. Residual solvent was removed from the coated film in a
convection oven maintained at a temperature of 150.degree. F.
(65.6.degree. C.); the oven length was 30 ft (9.14 m).
[0370] Microstructured film A was conveyed to a lamination station
and laminated to the adhesive side of the PET cover film with the
microstructured prismatic element side of the film in direct
contact with the adhesive coating. The laminator was configured
with a rubber roll (Shore A Durometer of 80) nipped against a steel
roll; the nip pressure was adjusted to 90 psi to imbed the
microstructured prismatic elements into the adhesive.
[0371] The laminate was conveyed to a UV curing station, where it
was exposed to actinic radiation. The radiation source was
positioned so that the adhesive was irradiated through the film
comprising the microstructured prismatic elements. The curing
station was comprised of a Fusion UV System (Gaithersburg Md.) and
a temperature controlled steel backup roll. The Fusion UV source
was configured with a D Bulb and an aluminum reflector with power
setting range of 70%. The UV backup roll was maintained at a
temperature of 70.degree. F. (21.1.degree. C.).
TABLE-US-00008 TABLE 8 Peel strength and Glare of Example 2 at
different adhesive thickness. Adhesive thickness Peel strength Max
Direct Glare (microns) (gram/inch) (% of incident) 3.0 174 20.1 3.4
203 16.1 4.5 240 14.6
Example 3
[0372] A window film pressure sensitive adhesive was coated on the
first plano side of a DuPont Melinex 454 PET cover film which was
75 micron (3 mil) thick and a release liner was then laminated to
the window film adhesive to produce a 3-layer laminate.
[0373] Adhesive solution 1 was coated on the second surface of the
Melinex 454 film of the 3-layer laminate using a slot-type die. The
adhesive solution was delivered using a gear driven pump at
specified flow rate to provide a 4.5 micron dry adhesive coating
thickness. Residual solvent was removed from the coated film in a
convection oven maintained at a temperature of 150.degree. F.
(65.6.degree. C.); the oven length was 30 ft (9.14 m).
[0374] Microstructured film A was conveyed to a lamination station
and laminated to the adhesive side of the PET cover film with the
microstructured prismatic element side of the film in direct
contact with the adhesive coating. The laminator was configured
with a rubber roll (Shore A Durometer of 80) nipped against a steel
roll; the nip pressure was adjusted to 90 psi to imbed the
microstructured prismatic elements into the adhesive.
[0375] The laminate was conveyed to a UV curing station, where it
was exposed to actinic radiation. The radiation source was
positioned so that the adhesive was irradiated through the film
comprising the microstructured prismatic elements. The curing
station was comprised of a Fusion UV System (Gaithersburg Md.) and
a temperature controlled steel backup roll. The Fusion UV source
was configured with a D Bulb and an aluminum reflector with power
setting range of 70%. The UV backup roll was maintained at a
temperature of 70.degree. F. (21.1.degree. C.).
Example 4
[0376] A window film adhesive was coated on the first major plano
side of a DuPont Melinex 454 PET cover film which was 75 micron (3
mil) thick and a release liner was laminated to the window film
adhesive to produce a 3-layer laminate.
[0377] Adhesive solution 2 was coated on the second surface of the
Melinex 454 film of the 3-layer laminate using a slot-type die. The
solution was delivered using a gear driven pump at specified flow
rate to provide a 4.5 micron dry adhesive coating thickness.
Residual solvent was removed from the coated film in a convection
oven maintained at a temperature of 150.degree. F. (65.6.degree.
C.); the oven length was 30 ft (9.14 m).
[0378] Microstructured film A was conveyed to a lamination station
and laminated to the adhesive side of the PET cover film with the
microstructured prismatic element side of the film in direct
contact with the adhesive coating. The laminator was configured
with a rubber roll (Shore A Durometer of 80) nipped against a steel
roll; the nip pressure was adjusted to 90 psi to imbed the
microstructured prismatic elements into the adhesive.
[0379] The laminate was conveyed to a UV curing station, where it
was exposed to actinic radiation. The radiation source was
positioned so that the adhesive was irradiated through the film
comprising the microstructured prismatic elements. The curing
station was comprised of a Fusion UV System (Gaithersburg Md.) and
a temperature controlled steel backup roll. The Fusion UV source
was configured with a D Bulb and an aluminum reflector with power
setting range of 70%. The UV backup roll was maintained at a
temperature of 70.degree. F. (21.1.degree. C.).
Example 5
[0380] A window film adhesive was coated on the first major plano
side of a DuPont Melinex 454 PET cover film which was 75 micron (3
mil) thick and a release liner was laminated to the window film
adhesive to produce a 3-layer laminate.
[0381] Adhesive solution 3 was coated on the second surface of the
Melinex 454 film of the 3-layer laminate using a slot-type die. The
solution was delivered using a gear driven pump at specified flow
rate to provide a 5.5 micron dry adhesive coating thickness.
Residual solvent was removed from the coated film in a convection
oven maintained at a temperature of 150.degree. F. (65.6.degree.
C.); the oven length was 30 ft (9.14 m).
[0382] Microstructured film A was conveyed to a lamination station
and laminated to the adhesive side of the PET cover film with the
microstructured prismatic element side of the film in direct
contact with the adhesive coating. The laminator was configured
with a rubber roll (Shore A Durometer of 80) nipped against a steel
roll; the nip pressure was adjusted to 90 psi to imbed the
microstructured prismatic elements into the adhesive.
[0383] The laminate was conveyed to a UV curing station, where it
was exposed to actinic radiation. The radiation source was
positioned so that the adhesive was irradiated through the film
comprising the microstructured prismatic elements. The curing
station was comprised of a Fusion UV System (Gaithersburg Md.) and
a temperature controlled steel backup roll. The Fusion UV source
was configured with a D Bulb and an aluminum reflector with power
setting range of 70%. The UV backup roll was maintained at a
temperature of 70.degree. F. (21.1.degree. C.). Results are in
Tables 9 and 10.
Testing and Aging of Daylight Redirecting Film Assembly:
Measurement of Interlayer Peel Strength of Daylight Redirecting
Film Assembly:
[0384] Peel force was measured using an IMASS SP-2000 tester
(available from IMASS Inc., Accord Mass.). Test strips 1 inch (2.54
cm) wide and approximately 10 in (25.4 cm) long were cut parallel
and perpendicular to the prism orientation of the bottom prism
film. Laminate strips were adhered to the tester platform using 1
inch (2.54 cm) wide Scotch double-coated tape (available as Scotch
665 from 3M Company, St. Paul Minn.). The tester was configured to
measure the 180 degree peel force. Samples were oriented so that
the plano side of the bottom prism film was adhered to the tester
platform and the top film was attached to the force balance. The
load cell capacity was 10 lbf (44.5 N). Peel force was measured at
a rate of 12 in/min (30.5 cm/min). Data were collected after an
initial delay of 2 seconds. Measurements were then averaged over a
test period of 20 seconds. For each sample, at least three test
strips with each of the parallel and perpendicular microstructured
prismatic element orientations were tested.
Measurement of Haze and Clarity:
[0385] Haze and clarity values disclosed herein were measured using
a Haze-Gard Plus haze meter (BYK-Gardiner, Silver Springs, Md.)
according to the procedure described in ASTM D1003. Optical haze,
as used herein, is defined as the ratio of the transmitted light
that deviates from the normal direction by more than 4 degrees to
the total transmitted light. Optical clarity is defined as
(T.sub.1-T.sub.2)/(T.sub.1+T.sub.2), where T.sub.1 is the
transmitted light that deviates from the normal direction between
zero and 0.7 degrees, and T.sub.2 is the transmitted light that
lies between 1.6 and 2 degrees from the normal direction. In all
cases, the optical films were measured with the cover film of the
laminate toward the light source.
Environmental Aging of Daylight Redirecting Film Assembly:
[0386] To test the environmental performance, the daylight
redirecting film assemblies, were placed in an environmental
chamber (Envirotronics, Grand Rapids Mich.). The chamber was
maintained at 65.degree. C. and 95% RH. Samples were typically aged
for a specified period. Unaged and aged daylight redirecting film
assemblies were cut and characterized according to the testing
procedures previously defined.
Glare Measurement Data
[0387] The optical performance of various light redirecting
structures as a function of illumination (input) angle was measured
using an imaging sphere for scatter and appearance measurement
(IS-SA) from Radiant Vision Systems (Richmond, Wash.) model
IS-SA-13-1. For each design, the hemispherical angular distribution
of the transmitted light (BTDF-Bidirectional Transmission
Distribution Function) was measured for illumination elevation
angles between 0 (normal, head on) and 75 degrees in 5 degree
increment. For this measurement, the azimuth of illumination was
constrained to be 0 deg with respect to the surface normal of the
window to which the light redirecting structures are attached.
[0388] The redirected light was measured as a function of the
output angles .quadrature..sub.x and .quadrature..sub.y, the
Cartesian components of spherical coordinates
.quadrature..quadrature. and .quadrature..quadrature. where the x
and y subscripts refer to the horizontal and vertical directions
respectively. (.quadrature..sub.x=.quadrature..quadrature. cos
.quadrature. and .quadrature..sub.y=.quadrature..quadrature. sin
.quadrature. and .quadrature.=0 by definition when the output angle
falls on the positive x axis.)
[0389] Light going over and under the horizon is more or less
useful and so we define zones to group light that is similarly
useful. We define each zone by maximum and minimum limits on
.quadrature..sub.y. Then the zonal transmittance can be defined to
be the integral of the BTDF over the solid angle defined by that
zone, that is, for all .quadrature..sub.x for each
.quadrature..sub.y between .quadrature..sub.y min and
.quadrature..sub.y max. The resulting integrand is called the zonal
transmission and is a fraction of the total amount of light
incident on the structures.
[0390] In particular, light that is directed below horizontal is
undesirable. If it is directed down at a steep angle, it is wasted
on the floor close to the window. If it is directed down but at a
less steep angle, it is not only wasted but it becomes glare, which
is bothersome to room occupants.
[0391] Direct Glare is defined as the fraction of light transmitted
between 0 and 15 deg downwards and was determined for each
structure and illumination elevation angle from the measured BTDF.
FIG. 33 shows the amount of Direct Glare as function of sun
elevation for three light directing films with varying adhesive
thickness. As the adhesive thickness is increased, the Direct Glare
also increases. Also, as shown in Table 4, as the adhesive
thickness is increased, the interlayer peel strength increased.
Color Measurement Data
[0392] We choose to quantify the color shift as the distance
between the input color and the transmitted color as plotted on the
perceptively uniform CIE 1976 UCS Chromaticity Diagram, which has
the coordinates u' and v'. For example we can measure the color of
the input illumination with a Minolta CS-100 Chroma Meter as
scattered by a flat white object and compare that chromaticity vs.
the chromaticity at a particular output angle by calculating the
color shift as the distance between the two coordinates. We define
.DELTA.u'v'= {square root over
(u'-u'.sub.0).sup.2+(v'-v'.sub.0).sup.2)} where u'.sub.0 and
v'.sub.0 are the measured chromaticity of the light transmitted
through the window but not through the light redirecting films and
as scattered from a flat-white object. Therefore S.sub.0 describes
the color shift away from the color of the input light.
[0393] For example Table 9 contains measurements comparing two
types of light redirecting films mounted in a south facing window.
At the time of the measurement the sun elevation was 60.91 deg and
the sun azimuth was 197.43 deg. The films were observed from 25 ft
away from the windows. The measurement spot was 9 ft above the
floor. The measurement of the input color is listed at the bottom
as the "Window transmission" and the last column shows the
calculated color shift from this color. The "Left DRF" has a larger
color shift than the "Right DRF." These chromaticity measurements
are plotted in FIG. 35. Lines connect the two measured points. The
length of these lines are equal to .quadrature.u'v'.
TABLE-US-00009 TABLE 9 Peel strength at different bead loading %.
Adhesive Thickness (microns) % Beads Average Peel (g/inch) 4.5 0
362 4.5 5 182 5.5 10 223
TABLE-US-00010 TABLE 10 Color measurements at different bead
loading %. Y u' v' .quadrature.u'v' No beads 9010 0.242 0.498
0.028474 5% beads 7110 0.229 0.494 0.018092 Window transmission*
4690 0.214 0.504 0 *as scattered from a flat white surface an hour
later.
Exemplary Embodiments: Film Construction A
[0394] 1. A film construction A comprising: [0395] a light
redirecting film having a first major surface and a second major
surface opposite the first major surface, [0396] wherein the first
major surface of the light redirecting film comprises a plurality
of microstructured prismatic elements, [0397] wherein one or more
of the microstructured prismatic elements have a first peak and a
second peak, [0398] wherein the first peak has a height H1 and the
second peak has a height H2, [0399] wherein H3 is H1-H2, and H3 is
equal or greater than 1 micron, [0400] an adhesive layer comprising
an adhesive, wherein the adhesive layer has a first major surface
and a second major surface opposite the first major surface, [0401]
a cover film having a first major surface and a second major
surface opposite the first major surface, wherein the first peak of
one or more of the microstructured prismatic elements penetrates at
least partially into the first major surface of the adhesive layer,
[0402] wherein the second major surface of the adhesive layer is
adjacent to the first major surface of the cover film. [0403] 2.
The film construction according to any of the preceding embodiments
directed to film construction A, wherein H3 is from 1 micron to 30
microns. [0404] 3. The film construction according to any of the
preceding embodiments directed to film construction A, wherein H3
is from 1 micron to 20 microns. [0405] 4. The film construction
according to any of the preceding embodiments directed to film
construction A, wherein H3 is from 1 micron to 10 microns. [0406]
5. The film construction according to any of the preceding
embodiments directed to film construction A, wherein the first
major surface of the light redirecting film is bonded to the first
major surface of the adhesive layer, [0407] 6. The film
construction according to any of the preceding embodiments directed
to film construction A, wherein the second major surface of the
adhesive layer is bonded to the first major surface of the cover
film [0408] 7. The film construction according to any of the
preceding embodiments directed to film construction A, wherein H3
is from 2 microns to 8 microns. [0409] 8. The film construction
according to any of the preceding embodiments directed to film
construction A, wherein H3 is from 2 microns to 5 microns. [0410]
9. The film construction according to any of the preceding
embodiments directed to film construction A, wherein the ratio
H1/H2 is less than or equal to 5. [0411] 10. The film construction
according to any of the preceding embodiments directed to film
construction A, wherein the second major surface of the adhesive
layer is immediately adjacent to the first major surface of the
film. [0412] 11. The film construction according to any of the
preceding embodiments directed to film construction A, wherein when
the film construction is in a vertical position, the first peak of
the microstructured prismatic element is positionally located above
the second peak. [0413] 12. The film construction according to any
of the preceding embodiments directed to film construction A,
wherein at least 50% of the microstructured prismatic elements have
a first peak and a second peak. [0414] 13. The film construction
according to any of the preceding embodiments directed to film
construction A, wherein at least 75% of the microstructured
prismatic elements have a first peak and a second peak. [0415] 14.
The film construction according to any of the preceding embodiments
directed to film construction A, wherein at least 90% of the
microstructured prismatic elements have a first peak and a second
peak. [0416] 15. The film construction according to any of the
preceding embodiments directed to film construction A, wherein at
least 95% of the microstructured prismatic elements have a first
peak and a second peak. [0417] 16. The film construction according
to any of the preceding embodiments directed to film construction
A, wherein at least 98% of the microstructured prismatic elements
have a first peak and a second peak. [0418] 17. The film
construction according to any of the preceding embodiments directed
to film construction A, wherein at least 99% of the microstructured
prismatic elements have a first peak and a second peak. [0419] 18.
The film construction according to any of the preceding embodiments
directed to film construction A, wherein the microstructured
prismatic elements are arranged in contiguous rows on the first
major surface of the light redirecting film, and wherein every
other microstructured prismatic element within a row has a first
peak and a second peak. [0420] 19. The film construction according
to any of the preceding embodiments directed to film construction
A, wherein the microstructured prismatic elements are arranged in
contiguous rows on the first major surface of the light redirecting
film, and wherein every nth microstructured prismatic element
within a row has a first peak and a second peak, wherein n is an
integer from 3 to 25. [0421] 20. The film construction according to
any of the preceding embodiments directed to film construction A,
wherein the microstructured prismatic elements are arranged in
contiguous rows on the first major surface of the light redirecting
film, and wherein every nth microstructured prismatic element
within a row has a first peak and a second peak, wherein n is 3.
[0422] 21. The film construction according to any of the preceding
embodiments directed to film construction A, wherein the
microstructured prismatic elements are arranged in contiguous rows
on the first major surface of the light redirecting film, and
wherein every nth microstructured prismatic element within a row
has a first peak and a second peak, wherein n is 5. [0423] 22. The
film construction according to any of the preceding embodiments
directed to film construction A, wherein the microstructured
prismatic elements are arranged in contiguous rows on the first
major surface of the light redirecting film, and wherein every nth
microstructured prismatic element within a row has a first peak and
a second peak, wherein n is 10. [0424] 23. The film construction
according to any of the preceding embodiments directed to film
construction A, wherein the microstructured prismatic elements are
arranged in contiguous rows on the first major surface of the light
redirecting film, and wherein every nth microstructured prismatic
element within a row has a first peak and a second peak, wherein n
is 13. [0425] 24. The film construction according to any of the
preceding embodiments directed to film construction A, wherein the
microstructured prismatic elements are arranged in contiguous rows
on the first major surface of the light redirecting film, and
wherein every nth microstructured prismatic element within a row
has a first peak and a second peak, wherein n is 15. [0426] 25. The
film construction according to any of the preceding embodiments
directed to film construction A, wherein the microstructured
prismatic elements are arranged in contiguous rows on the first
major surface of the light redirecting film, and wherein every nth
microstructured prismatic element within a row has a first peak and
a second peak, wherein n is 20. [0427] 26. The film construction
according to any of the preceding embodiments directed to film
construction A, wherein the peel strength of the construction
between the light redirecting layer and the cover film is 30
gr/inch or more. [0428] 27. The film construction according to any
of the preceding embodiments directed to film construction A,
wherein the peel strength of the construction between the light
redirecting layer and the cover film is from 30 gr/inch to 1000
gr/inch. [0429] 28. The film construction according to any of the
preceding embodiments directed to film construction A, wherein the
peel strength of the construction between the light redirecting
layer and the cover film is from 50 gr/inch to 1000 gr/inch. [0430]
29. The film construction according to any of the preceding
embodiments directed to film construction A, wherein the peel
strength of the construction between the light redirecting layer
and the cover film is from 100 gr/inch to 1000 gr/inch. [0431] 30.
The film construction according to any of the preceding embodiments
directed to film construction A, wherein the peel strength of the
construction between the light redirecting layer and the cover film
is from 30 gr/inch to 500 gr/inch. [0432] 31. The film construction
according to any of the preceding embodiments directed to film
construction A, wherein the peel strength of the construction
between the light redirecting layer and the cover film is from 50
gr/inch to 500 gr/inch. [0433] 32. The film construction according
to any of the preceding embodiments directed to film construction
A, wherein the peel strength of the construction between the light
redirecting layer and the cover film is from 100 gr/inch to 500
gr/inch. [0434] 33. The film construction according to any of the
preceding embodiments directed to film construction A, wherein the
peel strength of the construction between the light redirecting
layer and the cover film is from 150 gr/inch to 500 gr/inch. [0435]
34. The film construction according to any of the preceding
embodiments directed to film construction A, wherein the peel
strength of the construction between the light redirecting layer
and the cover film is from 200 gr/inch to 500 gr/inch. [0436] 35.
The film construction according to any of the preceding embodiments
directed to film construction A, wherein the peel strength of the
construction between the light redirecting layer and the cover film
is from 250 gr/inch to 500 gr/inch. [0437] 36. The film
construction according to any of the preceding embodiments directed
to film construction A, wherein one or more of the microstructured
prismatic elements that have a first peak and a second peak, each
has a pitch, a height, and a valley angle, a first included angle
(alpha), and a second included angle (beta), wherein: [0438] the
pitch is 40.+-.3 microns; [0439] the height is 55.+-.3 microns;
[0440] the valley angle is 72.+-.2 degrees; [0441] the angle alpha
is 17.+-.2 degrees; and [0442] the angle beta is 10.+-.2 degrees.
[0443] 37. The film construction according to any of the preceding
embodiments directed to film construction A, wherein one or more of
the microstructured prismatic elements that have a first peak and a
second peak, each has a pitch, a height, and a valley angle, a
first included angle (alpha), and a second included angle (beta),
wherein: [0444] the pitch is 50.+-.3 microns; [0445] the height is
68.+-.3 microns; [0446] the valley angle is 72.+-.2 degrees; [0447]
the angle alpha is 17.+-.2 degrees; and [0448] the angle beta is
10.+-.2 degrees. [0449] 38. The film construction according to any
of the preceding embodiments directed to film construction A,
wherein one or more of the microstructured prismatic elements that
have a first peak and a second peak, each has a pitch, a height,
and a valley angle, a first included angle (alpha), and a second
included angle (beta), wherein: [0450] the pitch is from 35 to 55
microns; [0451] the height is from 45 to 78 microns; [0452] the
aspect ratio is from 1.2 to 1.5; [0453] the valley angle is from 60
to 80 degrees; [0454] the angle alpha is from 15 to 25 degrees; and
[0455] the angle beta is from 5 to 15 degrees. [0456] 39. The film
construction according to any of the preceding embodiments directed
to film construction A, wherein one or more of the microstructured
prismatic elements that have a first peak and a second peak, each
has a pitch, a height, and a valley angle, a first included angle
(alpha), and a second included angle (beta), wherein: [0457] the
pitch is from 35 to 55 microns; [0458] the height is from 40 to 72
microns; [0459] the aspect ratio is from 1.1 to 1.3; [0460] the
valley angle is from 50 to 70 degrees; [0461] the angle alpha is
from 18 to 28 degrees; and [0462] the angle beta is from 4 to 12
degrees. [0463] 40. The film construction according to any of the
preceding embodiments directed to film construction A, wherein one
or more of the microstructured prismatic elements that have a first
peak and a second peak, each has a pitch, a height, and a valley
angle, a first included angle (alpha), and a second included angle
(beta), wherein: [0464] the pitch is 40.+-.3 microns; [0465] the
height is 50.+-.3 microns; [0466] the valley angle is 60.+-.2
degrees; [0467] the angle alpha is 23.+-.2 degrees; and [0468] the
angle beta is 7.+-.2 degrees. [0469] 41. The film construction
according to any of the preceding embodiments directed to film
construction A, wherein one or more of the microstructured
prismatic elements that have a first peak and a second peak, each
has a pitch, a height, and a valley angle, a first included angle
(alpha), and a second included angle (beta), wherein: [0470] the
pitch is 50.+-.2 microns; [0471] the height is 61.+-.2 microns;
[0472] the valley angle is 60.+-.2 degrees; [0473] the angle alpha
is 23.+-.2 degrees; and [0474] the angle beta is 7.+-.2 degrees.
[0475] 42. The film construction according to any of the preceding
embodiments directed to film construction A, wherein one or more of
the microstructured prismatic elements that have a first peak and a
second peak, each has a pitch, a height, and a valley angle, a
first included angle (alpha), and a second included angle (beta),
wherein: [0476] the pitch is from 35 to 55 microns; [0477] the
height is from 45 to 78 microns; [0478] the aspect ratio is from
1.2 to 1.5; [0479] the valley angle is from 60 to 80 degrees;
[0480] the angle alpha is from 5 to 15 degrees; and [0481] the
angle beta is from 5 to 15 degrees. [0482] 43. The film
construction according to any of the preceding embodiments directed
to film construction A, wherein one or more of the microstructured
prismatic elements that have a first peak and a second peak, each
has a pitch, a height, and a valley angle, a first included angle
(alpha), and a second included angle (beta), wherein: [0483] the
pitch is 40.+-.2 microns; [0484] the height is 55.+-.2 microns;
[0485] the valley angle is 72.+-.2 degrees; [0486] the angle alpha
is 10.+-.2 degrees; and [0487] the angle beta is 10.+-.2 degrees.
[0488] 44. The film construction according to any of the preceding
embodiments directed to film construction A, wherein one or more of
the microstructured prismatic elements that have a first peak and a
second peak, each has a pitch, a height, and a valley angle, a
first included angle (alpha), and a second included angle (beta),
wherein: [0489] the pitch is 50.+-.2 microns; [0490] the height is
69.+-.2 microns; [0491] the valley angle is 72.+-.2 degrees; [0492]
the angle alpha is 10.+-.2 degrees; and [0493] the angle beta is
10.+-.2 degrees. [0494] 45. The film construction according to any
of the preceding embodiments directed to film construction A,
wherein one or more of the microstructured prismatic elements that
have a first peak and a second peak, each has a pitch, a height,
and a valley angle, a first included angle (alpha), and a second
included angle (beta), wherein:
[0495] the pitch is from 35 to 55 microns; [0496] the height is
from 45 to 78 microns; [0497] the aspect ratio is from 1.2 to 1.4;
[0498] the valley angle is from 60 to 80 degrees; [0499] the angle
alpha is from 10 to 25 degrees; and [0500] the angle beta is from 5
to 16 degrees. [0501] 46. The film construction according to any of
the preceding embodiments directed to film construction A, wherein
one or more of the microstructured prismatic elements that have a
first peak and a second peak, each has a pitch, a height, and a
valley angle, a first included angle (alpha), and a second included
angle (beta), wherein: [0502] the pitch is 40.+-.2 microns; [0503]
the height is 52.+-.2 microns; [0504] the valley angle is 74.+-.2
degrees; [0505] the angle alpha is 17.+-.2 degrees; and [0506] the
angle beta is 12.+-.2 degrees. [0507] 47. The film construction
according to any of the preceding embodiments directed to film
construction A, wherein one or more of the microstructured
prismatic elements that have a first peak and a second peak, each
has a pitch, a height, and a valley angle, a first included angle
(alpha), and a second included angle (beta), wherein: [0508] the
pitch is 50.+-.2 microns; [0509] the height is 66.+-.2 microns;
[0510] the valley angle is 74.+-.2 degrees; [0511] the angle alpha
is 17.+-.2 degrees; and [0512] the angle beta is 12.+-.2 degrees.
[0513] 48. The film construction according to any of the preceding
embodiments directed to film construction A, wherein
H1>H2>H3>0 microns, and wherein H3 is less than 10
microns. [0514] 49. The film construction according to any of the
preceding embodiments directed to film construction A, wherein
H1>H2>H3>0 microns, and wherein H3 is less than 8 microns.
[0515] 50. The film construction according to any of the preceding
embodiments directed to film construction A, wherein
H1>H2>H3>0 microns, and wherein H3 is less than 6 microns.
[0516] 51. The film construction according to any of the preceding
embodiments directed to film construction A, wherein
H1>H2>H3>0 microns, and wherein H3 is less than 4 microns.
[0517] 52. The film construction according to any of the preceding
embodiments directed to film construction A, wherein the first peak
has an apex angle B1 and the second peak has an apex angle B2, and
wherein B1<B2. [0518] 53. The film construction according to any
of the preceding embodiments directed to film construction A,
wherein the light redirecting film comprises a light redirecting
substrate having first and second major surfaces, and wherein the
plurality of the microstructured prismatic elements are on the
second major surface of the light redirecting substrate. [0519] 54.
The film construction according to any of the preceding embodiments
directed to film construction A, wherein the light redirecting film
comprises a light redirecting substrate having first and second
major surfaces, and wherein the plurality of the microstructured
prismatic elements are on the second major surface of the light
redirecting substrate, and wherein the material of the light
redirecting substrate is different from the material of plurality
of microstructured prismatic elements. [0520] 55. The film
construction according to any of the preceding embodiments directed
to film construction A, wherein the light redirecting film
comprises a light redirecting substrate having first and second
major surfaces, and wherein the plurality of the microstructured
prismatic elements are on the second major surface of the light
redirecting substrate, and wherein the material of the light
redirecting substrate is the same as the material of plurality of
microstructured prismatic elements. [0521] 56. The film
construction according to any of the preceding embodiments directed
to film construction A, wherein the material of the plurality of
microstructured prismatic elements has refractive index from 1.25
to 1.65. [0522] 57. The film construction according to any of the
preceding embodiments directed to film construction A, wherein the
material of the plurality of microstructured prismatic elements has
refractive index from 1.35 to 1.65 [0523] 58. The film construction
according to any of the preceding embodiments directed to film
construction A, wherein the light redirecting film comprises a
light redirecting substrate having first and second major surfaces,
and wherein the plurality of the microstructured prismatic elements
are on the second major surface of the light redirecting substrate,
and wherein the light redirecting substrate diffuses visible light.
[0524] 59. The film construction according to any of the preceding
embodiments directed to film construction A, wherein the film
construction further comprises a diffuser chosen from bulk
diffusers, surface diffusers, embedded diffusers, and combinations
thereof [0525] 60. The film construction according to any of the
preceding embodiments directed to film construction A, wherein the
light redirecting film comprises a light redirecting substrate
having first and second major surfaces, and wherein the plurality
of the microstructured prismatic elements are on the second major
surface of the light redirecting substrate, and wherein the surface
roughness of the second major surface of the light redirecting
substrate diffuses visible light. [0526] 61. The film construction
according to any of the preceding embodiments directed to film
construction A, wherein the light redirecting film comprises a
light redirecting substrate having first and second major surfaces,
and wherein the plurality of the microstructured prismatic elements
are on the second major surface of the light redirecting substrate,
and wherein the surface roughness of the first major surface of the
light redirecting substrate diffuses visible light. [0527] 62. The
film construction according to any of the preceding embodiments
directed to film construction A, wherein the light redirecting film
comprises a light redirecting substrate having first and second
major surfaces, and wherein the plurality of the microstructured
prismatic elements are on the second major surface of the light
redirecting substrate, and wherein the film construction further
comprises a diffusing layer adjacent the first major surface of the
light redirecting substrate. [0528] 63. The film construction
according to any of the preceding embodiments directed to film
construction A, wherein the light redirecting film comprises a
light redirecting substrate having first and second major surfaces,
and wherein the plurality of the microstructured prismatic elements
are on the second major surface of the light redirecting substrate,
and wherein the film construction further comprises a diffusing
layer immediately adjacent the first major surface of the light
redirecting substrate. [0529] 64. The film construction according
to any of the preceding embodiments directed to film construction
A, wherein the film construction further comprises a diffusing
layer adjacent the second major surface of the cover film. [0530]
65. The film construction according to any of the preceding
embodiments directed to film construction A, wherein the film
construction further comprises a diffusing layer immediately
adjacent the second major surface of the cover film. [0531] 66. The
film construction according to any of the preceding embodiments
directed to film construction A, wherein the adhesive in the
adhesive layer is chosen from a pressure sensitive adhesive, a
thermoset adhesive, hot melt adhesive, a UV-curable adhesive, or a
combination thereof. [0532] 67. The film construction according to
any of the preceding embodiments directed to film construction A,
wherein the adhesive in the adhesive layer is an UV-curable
pressure sensitive adhesive. [0533] 68. The film construction
according to any of the preceding embodiments directed to film
construction A, wherein the adhesive layer comprises one or more UV
stabilizers. [0534] 69. The film construction according to any of
the preceding embodiments directed to film construction A, wherein
the adhesive in the adhesive layer is an UV-curable pressure
sensitive adhesive, and wherein, after the adhesive has been
UV-cured, the adhesive does not creep. [0535] 70. The film
construction according to any of the preceding embodiments directed
to film construction A, wherein the adhesive in the adhesive layer
comprises a diffusing agent. [0536] 71. The film construction
according to any of the preceding embodiments directed to film
construction A, wherein the adhesive in the adhesive layer
comprises a diffusing agent and the diffusing agent is chosen from
micro beads and nanoparticles. [0537] 72. The film construction
according to any of the preceding embodiments directed to film
construction A, wherein the adhesive in the adhesive layer
comprises a diffusing agent and the diffusing agent is chosen from
micro beads having average size from 0.1 microns to 100 microns.
[0538] 73. The film construction according to any of the preceding
embodiments directed to film construction A, wherein the adhesive
in the adhesive layer comprises a diffusing agent and the diffusing
agent is chosen from micro beads having average size from 0.5
microns to 50 microns. [0539] 74. The film construction according
to any of the preceding embodiments directed to film construction
A, wherein the adhesive in the adhesive layer comprises a diffusing
agent and the diffusing agent is chosen from micro beads having
average size from 0.7 microns to 20 microns. [0540] 75. The film
construction according to any of the preceding embodiments directed
to film construction A, wherein the adhesive in the adhesive layer
comprises a diffusing agent and the diffusing agent is chosen from
micro beads having average size from 1 micron to 5 microns. [0541]
76. The film construction according to any of the preceding
embodiments directed to film construction A, wherein the adhesive
in the adhesive layer comprises a diffusing agent and the diffusing
agent is chosen from nanoparticles having average size from 1 nm to
100 nm. [0542] 77. The film construction according to any of the
preceding embodiments directed to film construction A, wherein the
adhesive in the adhesive layer comprises a diffusing agent and the
diffusing agent is chosen from nanoparticles having average size
from 5 nm to 50 nm. [0543] 78. The film construction according to
any of the preceding embodiments directed to film construction A,
wherein the adhesive in the adhesive layer comprises a diffusing
agent and the diffusing agent is chosen from nanoparticles having
average size from 5 nm to 30 nm. [0544] 79. The film construction
according to any of the preceding embodiments directed to film
construction A, wherein the adhesive in the adhesive layer
comprises a diffusing agent and the diffusing agent is chosen from
nanoparticles having average size from 1 nm to 20 nm. [0545] 80.
The film construction according to any of the preceding embodiments
directed to film construction A, wherein the thickness of the
adhesive layer is from 1 micron to 30 microns. [0546] 81. The film
construction according to any of the preceding embodiments directed
to film construction A, wherein the thickness of the adhesive layer
is from 1 micron to 20 microns. [0547] 82. The film construction
according to any of the preceding embodiments directed to film
construction A, wherein the thickness of the adhesive layer is from
1 micron to 10 microns. [0548] 83. The film construction according
to any of the preceding embodiments directed to film construction
A, wherein the thickness of the adhesive layer is from 1 micron to
5 microns. [0549] 84. The film construction according to any of the
preceding embodiments directed to film construction A, wherein the
thickness of the adhesive layer is from 2 micron to 10 microns.
[0550] 85. The film construction according to any of the preceding
embodiments directed to film construction A, wherein the first peak
of one or more of the microstructured prismatic elements penetrates
from 1 micron to 10 microns into the first major surface of the
adhesive layer. [0551] 86. The film construction according to any
of the preceding embodiments directed to film construction A,
wherein the first peak of one or more of the microstructured
prismatic elements penetrates from 1 micron to 8 microns into the
first major surface of the adhesive layer. [0552] 87. The film
construction according to any of the preceding embodiments directed
to film construction A, wherein the first peak of one or more of
the microstructured prismatic elements penetrates from 1 micron to
6 microns into the first major surface of the adhesive layer.
[0553] 88. The film construction according to any of the preceding
embodiments directed to film construction A, wherein the first peak
of one or more of the microstructured prismatic elements penetrates
from 1 micron to 5 microns into the first major surface of the
adhesive layer. [0554] 89. The film construction according to any
of the preceding embodiments directed to film construction A,
wherein the first peak of one or more of the microstructured
prismatic elements penetrates from 1 micron to 4 microns into the
first major surface of the adhesive layer. [0555] 90. The film
construction according to any of the preceding embodiments directed
to film construction A, wherein the one or more of the
microstructured prismatic elements have one or more curved facets.
[0556] 91. The film construction according to any of the preceding
embodiments directed to film construction A, wherein the film
construction has a visible light transmission from 10 to 100%.
[0557] 92. The film construction according to any of the preceding
embodiments directed to film construction A, wherein the film
construction has a visible light transmission from 20 to 100%.
[0558] 93. The film construction according to any of the preceding
embodiments directed to film construction A, wherein the film
construction has a visible light transmission from 20 to 95%.
[0559] 94. The film construction according to any of the preceding
embodiments directed to film construction A, wherein the film
construction has a visible light transmission from 20 to 85%.
[0560] 95. The film construction according to any of the preceding
embodiments directed to film construction A, wherein the film
construction has a visible light transmission from 30 to 80%.
[0561] 96. The film construction according to any of the preceding
embodiments directed to film construction A, wherein the cover film
is an optical film. [0562] 97. The film construction according to
any of the preceding embodiments directed to film construction A,
wherein the cover film is an infrared-reflecting film. [0563] 98.
The film construction according to any of the preceding embodiments
directed to film construction A, wherein the cover film diffuses
visible light. [0564] 99. The film construction according to any of
the preceding embodiments directed to film construction A, wherein
the cover film diffuses visible light by having a diffuser chosen
from bulk diffusers, surface diffusers, embedded diffusers, and
combinations thereof.
[0565] 100. The film construction according to any of the preceding
embodiments directed to film construction A, wherein the second
major surface of the cover film comprises a coating. [0566] 101.
The film construction according to any of the preceding embodiments
directed to film construction A, wherein the second major surface
of the cover film comprises a coating chosen from hardcoats,
anti-scratch coatings, low-surface energy coatings, easy-clean
coatings, anti-glare coatings, and combinations thereof [0567] 102.
The film construction according to any of the preceding embodiments
directed to film construction A, wherein the film construction has
a rectangular or square shape and the edge of at least one side is
sealed with a sealing agent. [0568] 103. The film construction
according to any of the preceding embodiments directed to film
construction A, wherein the film construction has a rectangular or
square shape and the edge of at least one side is sealed with an
edge sealing tape. [0569] 104. The film construction according to
any of the preceding embodiments directed to film construction A,
wherein the film construction has a circular or ellipsoidal shape
and the edge of the film construction is sealed all around. [0570]
105. The film construction according to any of the preceding
embodiments directed to film construction A, wherein the film
construction has a circular or ellipsoidal shape and at least a
portion of the edge of the film construction is sealed with a
sealing agent. [0571] 106. The film construction according to any
of the preceding embodiments directed to film construction A,
wherein the film construction has a circular or ellipsoidal shape
and at least a portion of the edge of the film construction is
sealed with an edge sealing tape. [0572] 107. The film construction
according to any of the preceding embodiments directed to film
construction A, wherein the light redirecting film comprises a
light redirecting substrate having first and second major surfaces,
and wherein the plurality of the microstructured prismatic elements
are on the second major surface of the light redirecting substrate,
and wherein the film construction further comprises a window film
adhesive layer adjacent the first major surface of the light
redirecting substrate. [0573] 108. The film construction according
to any of the preceding embodiments directed to film construction
A, wherein the film construction further comprises a window film
adhesive layer adjacent the second major surface of the cover film.
[0574] 109. The film construction according to any of the preceding
embodiments directed to film construction A, wherein the film
construction further comprises a window film adhesive layer, and
the window film adhesive layer comprises one or more UV
stabilizers. [0575] 110. A window film comprising a film
construction as claimed as in any of the preceding embodiments
directed to film construction A. [0576] 111. A glazing unit
comprising a film construction as claimed as in any of the
preceding embodiments directed to film construction A.
Exemplary Embodiments: Film Construction B
[0576] [0577] 1. A film construction B comprising: [0578] a light
redirecting film having a first major surface and a second major
surface opposite the first major surface, [0579] wherein the first
major surface of the light redirecting film comprises a plurality
of microstructured prismatic elements, [0580] wherein one or more
of the microstructured prismatic elements have a first peak and a
second peak, [0581] wherein the first peak has a height H1 and the
second peak has a height H2, [0582] wherein H3 is H1-H2, and H3 is
from 1 microns to 8 microns, [0583] an adhesive layer comprising an
adhesive, wherein the adhesive layer has a first major surface and
a second major surface opposite the first major surface, [0584] a
cover film having a first major surface and a second major surface
opposite the first major surface, [0585] a diffusion layer, wherein
when the film construction is in a vertical position, the first
peak of the microstructured prismatic element is positionally
located above the second peak, wherein the first peak has an apex
angle B1 and the second peak has an apex angle B2, and wherein
B1<B2, wherein the first peak of one or more of the
microstructured prismatic elements penetrates at least partially
into the first major surface of the adhesive layer, wherein the
first major surface of the light redirecting film is bonded to the
first major surface of the adhesive layer, wherein the second major
surface of the adhesive layer is bonded to the first major surface
of the cover film. [0586] 2. The film construction according to any
of the preceding embodiments directed to film construction B,
wherein the first major surface of the light redirecting film is
bonded to the first major surface of the adhesive layer, [0587] 3.
The film construction according to any of the preceding embodiments
directed to film construction B, wherein the second major surface
of the adhesive layer is bonded to the first major surface of the
cover film [0588] 4. The film construction according to any of the
preceding embodiments directed to film construction B, wherein H3
is from 2 microns to 8 microns. [0589] 5. The film construction
according to any of the preceding embodiments directed to film
construction B, wherein H3 is from 2 microns to 5 microns. [0590]
6. The film construction according to any of the preceding
embodiments directed to film construction B, wherein the ratio
H1/H2 is less than or equal to 5. [0591] 7 The film construction
according to any of the preceding embodiments directed to film
construction B, wherein the second major surface of the adhesive
layer is immediately adjacent to the first major surface of the
film. [0592] 8. The film construction according to any of the
preceding embodiments directed to film construction B, wherein when
the film construction is in a vertical position, the first peak of
the microstructured prismatic element is positionally located above
the second peak. [0593] 9. The film construction according to any
of the preceding embodiments directed to film construction B,
wherein at least 50% of the microstructured prismatic elements have
a first peak and a second peak. [0594] 10. The film construction
according to any of the preceding embodiments directed to film
construction B, wherein at least 75% of the microstructured
prismatic elements have a first peak and a second peak. [0595] 11.
The film construction according to any of the preceding embodiments
directed to film construction B, wherein at least 90% of the
microstructured prismatic elements have a first peak and a second
peak. [0596] 12. The film construction according to any of the
preceding embodiments directed to film construction B, wherein at
least 95% of the microstructured prismatic elements have a first
peak and a second peak. [0597] 13. The film construction according
to any of the preceding embodiments directed to film construction
B, wherein at least 98% of the microstructured prismatic elements
have a first peak and a second peak. [0598] 14. The film
construction according to any of the preceding embodiments directed
to film construction B, wherein at least 99% of the microstructured
prismatic elements have a first peak and a second peak. [0599] 15.
The film construction according to any of the preceding embodiments
directed to film construction B, wherein the microstructured
prismatic elements are arranged in contiguous rows on the first
major surface of the light redirecting film, and wherein every
other microstructured prismatic element within a row has a first
peak and a second peak. [0600] 16. The film construction according
to any of the preceding embodiments directed to film construction
B, wherein the microstructured prismatic elements are arranged in
contiguous rows on the first major surface of the light redirecting
film, and wherein every nth microstructured prismatic element
within a row has a first peak and a second peak, wherein n is an
integer from 3 to 25. [0601] 17. The film construction according to
any of the preceding embodiments directed to film construction B,
wherein the microstructured prismatic elements are arranged in
contiguous rows on the first major surface of the light redirecting
film, and wherein every nth microstructured prismatic element
within a row has a first peak and a second peak, wherein n is 3.
[0602] 18. The film construction according to any of the preceding
embodiments directed to film construction B, wherein the
microstructured prismatic elements are arranged in contiguous rows
on the first major surface of the light redirecting film, and
wherein every nth microstructured prismatic element within a row
has a first peak and a second peak, wherein n is 5. [0603] 19. The
film construction according to any of the preceding embodiments
directed to film construction B, wherein the microstructured
prismatic elements are arranged in contiguous rows on the first
major surface of the light redirecting film, and wherein every nth
microstructured prismatic element within a row has a first peak and
a second peak, wherein n is 10. [0604] 20. The film construction
according to any of the preceding embodiments directed to film
construction B, wherein the microstructured prismatic elements are
arranged in contiguous rows on the first major surface of the light
redirecting film, and wherein every nth microstructured prismatic
element within a row has a first peak and a second peak, wherein n
is 13. [0605] 21. The film construction according to any of the
preceding embodiments directed to film construction B, wherein the
microstructured prismatic elements are arranged in contiguous rows
on the first major surface of the light redirecting film, and
wherein every nth microstructured prismatic element within a row
has a first peak and a second peak, wherein n is 15. [0606] 22. The
film construction according to any of the preceding embodiments
directed to film construction B, wherein the microstructured
prismatic elements are arranged in contiguous rows on the first
major surface of the light redirecting film, and wherein every nth
microstructured prismatic element within a row has a first peak and
a second peak, wherein n is 20. [0607] 23. The film construction
according to any of the preceding embodiments directed to film
construction B, wherein the peel strength of the construction
between the light redirecting layer and the cover film is 30
gr/inch or more. [0608] 24. The film construction according to any
of the preceding embodiments directed to film construction B,
wherein the peel strength of the construction between the light
redirecting layer and the cover film is from 30 gr/inch to 1000
gr/inch. [0609] 25. The film construction according to any of the
preceding embodiments directed to film construction B, wherein the
peel strength of the construction between the light redirecting
layer and the cover film is from 50 gr/inch to 1000 gr/inch. [0610]
26. The film construction according to any of the preceding
embodiments directed to film construction B, wherein the peel
strength of the construction between the light redirecting layer
and the cover film is from 100 gr/inch to 1000 gr/inch. [0611] 27.
The film construction according to any of the preceding embodiments
directed to film construction B, wherein the peel strength of the
construction between the light redirecting layer and the cover film
is from 30 gr/inch to 500 gr/inch. [0612] 28. The film construction
according to any of the preceding embodiments directed to film
construction B, wherein the peel strength of the construction
between the light redirecting layer and the cover film is from 50
gr/inch to 500 gr/inch. [0613] 29. The film construction according
to any of the preceding embodiments directed to film construction
B, wherein the peel strength of the construction between the light
redirecting layer and the cover film is from 100 gr/inch to 500
gr/inch. [0614] 30. The film construction according to any of the
preceding embodiments directed to film construction B, wherein the
peel strength of the construction between the light redirecting
layer and the cover film is from 150 gr/inch to 500 gr/inch. [0615]
31. The film construction according to any of the preceding
embodiments directed to film construction B, wherein the peel
strength of the construction between the light redirecting layer
and the cover film is from 200 gr/inch to 500 gr/inch. [0616] 32.
The film construction according to any of the preceding embodiments
directed to film construction B, wherein the peel strength of the
construction between the light redirecting layer and the cover film
is from 250 gr/inch to 500 gr/inch. [0617] 33. The film
construction according to any of the preceding embodiments directed
to film construction B, wherein one or more of the microstructured
prismatic elements that have a first peak and a second peak, each
has a pitch, a height, and a valley angle, a first included angle
(alpha), and a second included angle (beta), wherein: [0618] the
pitch is 40.+-.3 microns; [0619] the height is 55.+-.3 microns;
[0620] the valley angle is 72.+-.2 degrees; [0621] the angle alpha
is 17.+-.2 degrees; and [0622] the angle beta is 10.+-.2 degrees.
[0623] 34. The film construction according to any of the preceding
embodiments directed to film construction B, wherein one or more of
the microstructured prismatic elements that have a first peak and a
second peak, each has a pitch, a height, and a valley angle, a
first included angle (alpha), and a second included angle (beta),
wherein: [0624] the pitch is 50.+-.3 microns; [0625] the height is
68.+-.3 microns; [0626] the valley angle is 72.+-.2 degrees; [0627]
the angle alpha is 17.+-.2 degrees; and [0628] the angle beta is
10.+-.2 degrees. [0629] 35. The film construction according to any
of the preceding embodiments directed to film construction B,
wherein one or more of the microstructured prismatic elements that
have a first peak and a second peak, each has a pitch, a height,
and a valley angle, a first included angle (alpha), and a second
included angle (beta), wherein: [0630] the pitch is from 35 to 55
microns; [0631] the height is from 45 to 78 microns; [0632] the
aspect ratio is from 1.2 to 1.5; [0633] the valley angle is from 60
to 80 degrees; [0634] the angle alpha is from 15 to 25 degrees; and
[0635] the angle beta is from 5 to 15 degrees. [0636] 36. The film
construction according to any of the preceding embodiments directed
to film construction B, wherein one or more of the microstructured
prismatic elements that have a first peak and a second peak, each
has a pitch, a height, and a valley angle, a first included angle
(alpha), and a second included angle (beta), wherein: [0637] the
pitch is from 35 to 55 microns; [0638] the height is from 40 to 72
microns; [0639] the aspect ratio is from 1.1 to 1.3; [0640] the
valley angle is from 50 to 70 degrees; [0641] the angle alpha is
from 18 to 28 degrees; and [0642] the angle beta is from 4 to 12
degrees. [0643] 37. The film construction according to any of the
preceding embodiments directed to film construction B, wherein one
or more of the microstructured prismatic elements that have a first
peak and a second peak, each has a pitch, a height, and a valley
angle, a first included angle (alpha), and a second included angle
(beta), wherein: [0644] the pitch is 40.+-.3 microns; [0645] the
height is 50.+-.3 microns; [0646] the valley angle is 60.+-.2
degrees; [0647] the angle alpha is 23.+-.2 degrees; and [0648] the
angle beta is 7.+-.2 degrees. [0649] 38. The film construction
according to any of the preceding embodiments directed to film
construction B, wherein one or more of the microstructured
prismatic elements that have a first peak and a second peak, each
has a pitch, a height, and a valley angle, a first included angle
(alpha), and a second included angle (beta), wherein: [0650] the
pitch is 50.+-.2 microns; [0651] the height is 61.+-.2 microns;
[0652] the valley angle is 60.+-.2 degrees; [0653] the angle alpha
is 23.+-.2 degrees; and [0654] the angle beta is 7.+-.2 degrees.
[0655] 39. The film construction according to any of the preceding
embodiments directed to film construction B, wherein one or more of
the microstructured prismatic elements that have a first peak and a
second peak, each has a pitch, a height, and a valley angle, a
first included angle (alpha), and a second included angle (beta),
wherein: [0656] the pitch is from 35 to 55 microns; [0657] the
height is from 45 to 78 microns; [0658] the aspect ratio is from
1.2 to 1.5; [0659] the valley angle is from 60 to 80 degrees;
[0660] the angle alpha is from 5 to 15 degrees; and [0661] the
angle beta is from 5 to 15 degrees. [0662] 40. The film
construction according to any of the preceding embodiments directed
to film construction B, wherein one or more of the microstructured
prismatic elements that have a first peak and a second peak, each
has a pitch, a height, and a valley angle, a first included angle
(alpha), and a second included angle (beta), wherein: [0663] the
pitch is 40.+-.2 microns; [0664] the height is 55.+-.2 microns;
[0665] the valley angle is 72.+-.2 degrees; [0666] the angle alpha
is 10.+-.2 degrees; and [0667] the angle beta is 10.+-.2 degrees.
[0668] 41. The film construction according to any of the preceding
embodiments directed to film construction B, wherein one or more of
the microstructured prismatic elements that have a first peak and a
second peak, each has a pitch, a height, and a valley angle, a
first included angle (alpha), and a second included angle (beta),
wherein: [0669] the pitch is 50.+-.2 microns; [0670] the height is
69.+-.2 microns; [0671] the valley angle is 72.+-.2 degrees; [0672]
the angle alpha is 10.+-.2 degrees; and [0673] the angle beta is
10.+-.2 degrees. [0674] 42. The film construction according to any
of the preceding embodiments directed to film construction B,
wherein one or more of the microstructured prismatic elements that
have a first peak and a second peak, each has a pitch, a height,
and a valley angle, a first included angle (alpha), and a second
included angle (beta), wherein:
[0675] the pitch is from 35 to 55 microns; [0676] the height is
from 45 to 78 microns; [0677] the aspect ratio is from 1.2 to 1.4;
[0678] the valley angle is from 60 to 80 degrees; [0679] the angle
alpha is from 10 to 25 degrees; and [0680] the angle beta is from 5
to 16 degrees. [0681] 43. The film construction according to any of
the preceding embodiments directed to film construction B, wherein
one or more of the microstructured prismatic elements that have a
first peak and a second peak, each has a pitch, a height, and a
valley angle, a first included angle (alpha), and a second included
angle (beta), wherein: [0682] the pitch is 40.+-.2 microns; [0683]
the height is 52.+-.2 microns; [0684] the valley angle is 74.+-.2
degrees; [0685] the angle alpha is 17.+-.2 degrees; and [0686] the
angle beta is 12.+-.2 degrees. [0687] 44. The film construction
according to any of the preceding embodiments directed to film
construction B, wherein one or more of the microstructured
prismatic elements that have a first peak and a second peak, each
has a pitch, a height, and a valley angle, a first included angle
(alpha), and a second included angle (beta), wherein: [0688] the
pitch is 50.+-.2 microns; [0689] the height is 66.+-.2 microns;
[0690] the valley angle is 74.+-.2 degrees; [0691] the angle alpha
is 17.+-.2 degrees; and [0692] the angle beta is 12.+-.2 degrees.
[0693] 45. The film construction according to any of the preceding
embodiments directed to film construction B, wherein
H1>H2>H3>0 microns, and wherein H3 is less than 10
microns. [0694] 46. The film construction according to any of the
preceding embodiments directed to film construction B, wherein
H1>H2>H3>0 microns, and wherein H3 is less than 8 microns.
[0695] 47. The film construction according to any of the preceding
embodiments directed to film construction B, wherein
H1>H2>H3>0 microns, and wherein H3 is less than 6 microns.
[0696] 48. The film construction according to any of the preceding
embodiments directed to film construction B, wherein
H1>H2>H3>0 microns, and wherein H3 is less than 4 microns.
[0697] 49. The film construction according to any of the preceding
embodiments directed to film construction B, wherein the first peak
has an apex angle B1 and the second peak has an apex angle B2, and
wherein B1<B2. [0698] 50. The film construction according to any
of the preceding embodiments directed to film construction B,
wherein the light redirecting film comprises a light redirecting
substrate having first and second major surfaces, and wherein the
plurality of the microstructured prismatic elements are on the
second major surface of the light redirecting substrate. [0699] 51.
The film construction according to any of the preceding embodiments
directed to film construction B, wherein the light redirecting film
comprises a light redirecting substrate having first and second
major surfaces, and wherein the plurality of the microstructured
prismatic elements are on the second major surface of the light
redirecting substrate, and wherein the material of the light
redirecting substrate is different from the material of plurality
of microstructured prismatic elements. [0700] 52. The film
construction according to any of the preceding embodiments directed
to film construction B, wherein the light redirecting film
comprises a light redirecting substrate having first and second
major surfaces, and wherein the plurality of the microstructured
prismatic elements are on the second major surface of the light
redirecting substrate, and wherein the material of the light
redirecting substrate is the same as the material of plurality of
microstructured prismatic elements. [0701] 53. The film
construction according to any of the preceding embodiments directed
to film construction B, wherein the material of the plurality of
microstructured prismatic elements has refractive index from 1.25
to 1.65. [0702] 54. The film construction according to any of the
preceding embodiments directed to film construction B, wherein the
material of the plurality of microstructured prismatic elements has
refractive index from 1.35 to 1.65 [0703] 55. The film construction
according to any of the preceding embodiments directed to film
construction B, wherein the light redirecting film comprises a
light redirecting substrate having first and second major surfaces,
and wherein the plurality of the microstructured prismatic elements
are on the second major surface of the light redirecting substrate,
and wherein the light redirecting substrate diffuses visible light.
[0704] 56. The film construction according to any of the preceding
embodiments directed to film construction B, wherein the film
construction further comprises a diffuser chosen from bulk
diffusers, surface diffusers, embedded diffusers, and combinations
thereof [0705] 57. The film construction according to any of the
preceding embodiments directed to film construction B, wherein the
light redirecting film comprises a light redirecting substrate
having first and second major surfaces, and wherein the plurality
of the microstructured prismatic elements are on the second major
surface of the light redirecting substrate, and wherein the surface
roughness of the second major surface of the light redirecting
substrate diffuses visible light. [0706] 58. The film construction
according to any of the preceding embodiments directed to film
construction B, wherein the light redirecting film comprises a
light redirecting substrate having first and second major surfaces,
and wherein the plurality of the microstructured prismatic elements
are on the second major surface of the light redirecting substrate,
and wherein the surface roughness of the first major surface of the
light redirecting substrate diffuses visible light. [0707] 59. The
film construction according to any of the preceding embodiments
directed to film construction B, wherein the light redirecting film
comprises a light redirecting substrate having first and second
major surfaces, and wherein the plurality of the microstructured
prismatic elements are on the second major surface of the light
redirecting substrate, and wherein the film construction further
comprises a diffusing layer adjacent the first major surface of the
light redirecting substrate. [0708] 60. The film construction
according to any of the preceding embodiments directed to film
construction B, wherein the light redirecting film comprises a
light redirecting substrate having first and second major surfaces,
and wherein the plurality of the microstructured prismatic elements
are on the second major surface of the light redirecting substrate,
and wherein the film construction further comprises a diffusing
layer immediately adjacent the first major surface of the light
redirecting substrate. [0709] 61. The film construction according
to any of the preceding embodiments directed to film construction
B, wherein the film construction further comprises a diffusing
layer adjacent the second major surface of the cover film. [0710]
62. The film construction according to any of the preceding
embodiments directed to film construction B, wherein the film
construction further comprises a diffusing layer immediately
adjacent the second major surface of the cover film. [0711] 63. The
film construction according to any of the preceding embodiments
directed to film construction B, wherein the adhesive in the
adhesive layer is chosen from a pressure sensitive adhesive, a
thermoset adhesive, hot melt adhesive, a UV-curable adhesive, or a
combination thereof. [0712] 64. The film construction according to
any of the preceding embodiments directed to film construction B,
wherein the adhesive in the adhesive layer is an UV-curable
pressure sensitive adhesive. [0713] 65. The film construction
according to any of the preceding embodiments directed to film
construction B, wherein the adhesive layer comprises one or more UV
stabilizers. [0714] 66. The film construction according to any of
the preceding embodiments directed to film construction B, wherein
the adhesive in the adhesive layer is an UV-curable pressure
sensitive adhesive, and wherein, after the adhesive has been
UV-cured, the adhesive does not creep. [0715] 67. The film
construction according to any of the preceding embodiments directed
to film construction B, wherein the adhesive in the adhesive layer
comprises a diffusing agent. [0716] 68. The film construction
according to any of the preceding embodiments directed to film
construction B, wherein the adhesive in the adhesive layer
comprises a diffusing agent and the diffusing agent is chosen from
micro beads and nanoparticles. [0717] 69. The film construction
according to any of the preceding embodiments directed to film
construction B, wherein the adhesive in the adhesive layer
comprises a diffusing agent and the diffusing agent is chosen from
micro beads having average size from 0.1 microns to 100 microns.
[0718] 70. The film construction according to any of the preceding
embodiments directed to film construction B, wherein the adhesive
in the adhesive layer comprises a diffusing agent and the diffusing
agent is chosen from micro beads having average size from 0.5
microns to 50 microns. [0719] 71. The film construction according
to any of the preceding embodiments directed to film construction
B, wherein the adhesive in the adhesive layer comprises a diffusing
agent and the diffusing agent is chosen from micro beads having
average size from 0.7 microns to 20 microns. [0720] 72. The film
construction according to any of the preceding embodiments directed
to film construction B, wherein the adhesive in the adhesive layer
comprises a diffusing agent and the diffusing agent is chosen from
micro beads having average size from 1 micron to 5 microns. [0721]
73. The film construction according to any of the preceding
embodiments directed to film construction B, wherein the adhesive
in the adhesive layer comprises a diffusing agent and the diffusing
agent is chosen from nanoparticles having average size from 1 nm to
100 nm. [0722] 74. The film construction according to any of the
preceding embodiments directed to film construction B, wherein the
adhesive in the adhesive layer comprises a diffusing agent and the
diffusing agent is chosen from nanoparticles having average size
from 5 nm to 50 nm. [0723] 75. The film construction according to
any of the preceding embodiments directed to film construction B,
wherein the adhesive in the adhesive layer comprises a diffusing
agent and the diffusing agent is chosen from nanoparticles having
average size from 5 nm to 30 nm. [0724] 76. The film construction
according to any of the preceding embodiments directed to film
construction B, wherein the adhesive in the adhesive layer
comprises a diffusing agent and the diffusing agent is chosen from
nanoparticles having average size from 1 nm to 20 nm. [0725] 77.
The film construction according to any of the preceding embodiments
directed to film construction B, wherein the thickness of the
adhesive layer is from 1 micron to 30 microns. [0726] 78. The film
construction according to any of the preceding embodiments directed
to film construction B, wherein the thickness of the adhesive layer
is from 1 micron to 20 microns. [0727] 79. The film construction
according to any of the preceding embodiments directed to film
construction B, wherein the thickness of the adhesive layer is from
1 micron to 10 microns. [0728] 80. The film construction according
to any of the preceding embodiments directed to film construction
B, wherein the thickness of the adhesive layer is from 1 micron to
5 microns. [0729] 81. The film construction according to any of the
preceding embodiments directed to film construction B, wherein the
thickness of the adhesive layer is from 2 micron to 10 microns.
[0730] 82. The film construction according to any of the preceding
embodiments directed to film construction B, wherein the first peak
of one or more of the microstructured prismatic elements penetrates
from 1 micron to 10 microns into the first major surface of the
adhesive layer. [0731] 83. The film construction according to any
of the preceding embodiments directed to film construction B,
wherein the first peak of one or more of the microstructured
prismatic elements penetrates from 1 micron to 8 microns into the
first major surface of the adhesive layer. [0732] 84. The film
construction according to any of the preceding embodiments directed
to film construction B, wherein the first peak of one or more of
the microstructured prismatic elements penetrates from 1 micron to
6 microns into the first major surface of the adhesive layer.
[0733] 85. The film construction according to any of the preceding
embodiments directed to film construction B, wherein the first peak
of one or more of the microstructured prismatic elements penetrates
from 1 micron to 5 microns into the first major surface of the
adhesive layer. [0734] 86. The film construction according to any
of the preceding embodiments directed to film construction B,
wherein the first peak of one or more of the microstructured
prismatic elements penetrates from 1 micron to 4 microns into the
first major surface of the adhesive layer. [0735] 87. The film
construction according to any of the preceding embodiments directed
to film construction B, wherein the one or more of the
microstructured prismatic elements have one or more curved facets.
[0736] 88. The film construction according to any of the preceding
embodiments directed to film construction B, wherein the film
construction has a visible light transmission from 10 to 100%.
[0737] 89. The film construction according to any of the preceding
embodiments directed to film construction B, wherein the film
construction has a visible light transmission from 20 to 100%.
[0738] 90. The film construction according to any of the preceding
embodiments directed to film construction B, wherein the film
construction has a visible light transmission from 20 to 95%.
[0739] 91. The film construction according to any of the preceding
embodiments directed to film construction B, wherein the film
construction has a visible light transmission from 20 to 85%.
[0740] 92. The film construction according to any of the preceding
embodiments directed to film construction B, wherein the film
construction has a visible light transmission from 30 to 80%.
[0741] 93. The film construction according to any of the preceding
embodiments directed to film construction B, wherein the cover film
is an optical film. [0742] 94. The film construction according to
any of the preceding embodiments directed to film construction B,
wherein the cover film is an infrared-reflecting film. [0743] 95.
The film construction according to any of the preceding embodiments
directed to film construction B, wherein the cover film diffuses
visible light. [0744] 96. The film construction according to any of
the preceding embodiments directed to film construction B, wherein
the cover film diffuses visible light by having a diffuser chosen
from bulk diffusers, surface diffusers, embedded diffusers, and
combinations thereof.
[0745] 97. The film construction according to any of the preceding
embodiments directed to film construction B, wherein the second
major surface of the cover film comprises a coating. [0746] 98. The
film construction according to any of the preceding embodiments
directed to film construction B, wherein the second major surface
of the cover film comprises a coating chosen from hardcoats,
anti-scratch coatings, low-surface energy coatings, easy-clean
coatings, anti-glare coatings, and combinations thereof [0747] 99.
The film construction according to any of the preceding embodiments
directed to film construction B, wherein the film construction has
a rectangular or square shape and the edge of at least one side is
sealed with a sealing agent. [0748] 100. The film construction
according to any of the preceding embodiments directed to film
construction B, wherein the film construction has a rectangular or
square shape and the edge of at least one side is sealed with an
edge sealing tape. [0749] 101. The film construction according to
any of the preceding embodiments directed to film construction B,
wherein the film construction has a circular or ellipsoidal shape
and the edge of the film construction is sealed all around. [0750]
102. The film construction according to any of the preceding
embodiments directed to film construction B, wherein the film
construction has a circular or ellipsoidal shape and at least a
portion of the edge of the film construction is sealed with a
sealing agent. [0751] 103. The film construction according to any
of the preceding embodiments directed to film construction B,
wherein the film construction has a circular or ellipsoidal shape
and at least a portion of the edge of the film construction is
sealed with an edge sealing tape. [0752] 104. The film construction
according to any of the preceding embodiments directed to film
construction B, wherein the light redirecting film comprises a
light redirecting substrate having first and second major surfaces,
and wherein the plurality of the microstructured prismatic elements
are on the second major surface of the light redirecting substrate,
and wherein the film construction further comprises a window film
adhesive layer adjacent the first major surface of the light
redirecting substrate. [0753] 105. The film construction according
to any of the preceding embodiments directed to film construction
B, wherein the film construction further comprises a window film
adhesive layer adjacent the second major surface of the cover film.
[0754] 106. The film construction according to any of the preceding
embodiments directed to film construction B, wherein the film
construction further comprises a window film adhesive layer, and
the window film adhesive layer comprises one or more UV
stabilizers. [0755] 107. A window film comprising a film
construction as claimed as in any of the preceding embodiments
directed to film construction B. [0756] 108. A glazing unit
comprising a film construction as claimed as in any of the
preceding embodiments directed to film construction B.
Exemplary Embodiments: Film Construction C
[0756] [0757] 1. A film construction C comprising: [0758] a light
redirecting film having a first major surface and a second major
surface opposite the first major surface, [0759] wherein the first
major surface of the light redirecting film comprises a plurality
of microstructured prismatic elements, [0760] wherein one or more
of the microstructured prismatic elements have a first peak, a
second peak, and a third peak, [0761] wherein the first peak has a
height H1, the second peak has a height H2, the third peak has a
height H3, [0762] wherein H1>H2 and H1>H3, [0763] wherein H4
is H1-H2, and H5 is H1-H3, and wherein H4 is from 1 microns to 10
microns and H5 is from 1 microns to 10 microns, [0764] an adhesive
layer comprising an adhesive, wherein the adhesive layer has a
first major surface and a second major surface opposite the first
major surface, [0765] a cover film having a first major surface and
a second major surface opposite the first major surface, wherein
when the film construction is in a vertical position, the first
peak of the microstructured prismatic element is: a) positionally
located above the second peak, b) positionally located above the
third peak, or positionally located above both the second peak and
the third peak, wherein the first peak has an apex angle B1, the
second peak has an apex angle B2, and the third peak has an apex
angle B3, wherein B1<B2 and B1<B3, wherein the first peak of
one or more of the microstructured prismatic elements penetrates at
least partially into the first major surface of the adhesive layer,
wherein the first major surface of the light redirecting film is
bonded to the first major surface of the adhesive layer, wherein
the second major surface of the adhesive layer is bonded to the
first major surface of the cover film. [0766] 2. The film
construction according to any of the preceding embodiments directed
to film construction C, wherein H3 is from 1 micron to 30 microns.
[0767] 3. The film construction according to any of the preceding
embodiments directed to film construction C, wherein H3 is from 1
micron to 20 microns. [0768] 4. The film construction according to
any of the preceding embodiments directed to film construction C,
wherein H3 is from 1 micron to 10 microns. [0769] 5. The film
construction according to any of the preceding embodiments directed
to film construction C, wherein the first major surface of the
light redirecting film is bonded to the first major surface of the
adhesive layer, [0770] 6. The film construction according to any of
the preceding embodiments directed to film construction C, wherein
the second major surface of the adhesive layer is bonded to the
first major surface of the cover film [0771] 7. The film
construction according to any of the preceding embodiments directed
to film construction C, wherein H3 is from 2 microns to 8 microns.
[0772] 8. The film construction according to any of the preceding
embodiments directed to film construction C, wherein H3 is from 2
microns to 5 microns. [0773] 9. The film construction according to
any of the preceding embodiments directed to film construction C,
wherein the ratio H1/H2 is less than or equal to 5. [0774] 10. The
film construction according to any of the preceding embodiments
directed to film construction C, wherein the second major surface
of the adhesive layer is immediately adjacent to the first major
surface of the film. [0775] 11. The film construction according to
any of the preceding embodiments directed to film construction C,
wherein when the film construction is in a vertical position, the
first peak of the microstructured prismatic element is positionally
located above the second peak. [0776] 12. The film construction
according to any of the preceding embodiments directed to film
construction C, wherein at least 50% of the microstructured
prismatic elements have a first peak and a second peak. [0777] 13.
The film construction according to any of the preceding embodiments
directed to film construction C, wherein at least 75% of the
microstructured prismatic elements have a first peak and a second
peak. [0778] 14. The film construction according to any of the
preceding embodiments directed to film construction C, wherein at
least 90% of the microstructured prismatic elements have a first
peak and a second peak. [0779] 15. The film construction according
to any of the preceding embodiments directed to film construction
C, wherein at least 95% of the microstructured prismatic elements
have a first peak and a second peak. [0780] 16. The film
construction according to any of the preceding embodiments directed
to film construction C, wherein at least 98% of the microstructured
prismatic elements have a first peak and a second peak. [0781] 17.
The film construction according to any of the preceding embodiments
directed to film construction C, wherein at least 99% of the
microstructured prismatic elements have a first peak and a second
peak. [0782] 18. The film construction according to any of the
preceding embodiments directed to film construction C, wherein the
microstructured prismatic elements are arranged in contiguous rows
on the first major surface of the light redirecting film, and
wherein every other microstructured prismatic element within a row
has a first peak and a second peak. [0783] 19. The film
construction according to any of the preceding embodiments directed
to film construction C, wherein the microstructured prismatic
elements are arranged in contiguous rows on the first major surface
of the light redirecting film, and wherein every nth
microstructured prismatic element within a row has a first peak and
a second peak, wherein n is an integer from 3 to 25. [0784] 20. The
film construction according to any of the preceding embodiments
directed to film construction C, wherein the microstructured
prismatic elements are arranged in contiguous rows on the first
major surface of the light redirecting film, and wherein every nth
microstructured prismatic element within a row has a first peak and
a second peak, wherein n is 3. [0785] 21. The film construction
according to any of the preceding embodiments directed to film
construction C, wherein the microstructured prismatic elements are
arranged in contiguous rows on the first major surface of the light
redirecting film, and wherein every nth microstructured prismatic
element within a row has a first peak and a second peak, wherein n
is 5. [0786] 22. The film construction according to any of the
preceding embodiments directed to film construction C, wherein the
microstructured prismatic elements are arranged in contiguous rows
on the first major surface of the light redirecting film, and
wherein every nth microstructured prismatic element within a row
has a first peak and a second peak, wherein n is 10. [0787] 23. The
film construction according to any of the preceding embodiments
directed to film construction C, wherein the microstructured
prismatic elements are arranged in contiguous rows on the first
major surface of the light redirecting film, and wherein every nth
microstructured prismatic element within a row has a first peak and
a second peak, wherein n is 13. [0788] 24. The film construction
according to any of the preceding embodiments directed to film
construction C, wherein the microstructured prismatic elements are
arranged in contiguous rows on the first major surface of the light
redirecting film, and wherein every nth microstructured prismatic
element within a row has a first peak and a second peak, wherein n
is 15. [0789] 25. The film construction according to any of the
preceding embodiments directed to film construction C, wherein the
microstructured prismatic elements are arranged in contiguous rows
on the first major surface of the light redirecting film, and
wherein every nth microstructured prismatic element within a row
has a first peak and a second peak, wherein n is 20. [0790] 26. The
film construction according to any of the preceding embodiments
directed to film construction C, wherein the peel strength of the
construction between the light redirecting layer and the cover film
is 30 gr/inch or more. [0791] 27. The film construction according
to any of the preceding embodiments directed to film construction
C, wherein the peel strength of the construction between the light
redirecting layer and the cover film is from 30 gr/inch to 1000
gr/inch. [0792] 28. The film construction according to any of the
preceding embodiments directed to film construction C, wherein the
peel strength of the construction between the light redirecting
layer and the cover film is from 50 gr/inch to 1000 gr/inch. [0793]
29. The film construction according to any of the preceding
embodiments directed to film construction C, wherein the peel
strength of the construction between the light redirecting layer
and the cover film is from 100 gr/inch to 1000 gr/inch. [0794] 30.
The film construction according to any of the preceding embodiments
directed to film construction C, wherein the peel strength of the
construction between the light redirecting layer and the cover film
is from 30 gr/inch to 500 gr/inch. [0795] 31. The film construction
according to any of the preceding embodiments directed to film
construction C, wherein the peel strength of the construction
between the light redirecting layer and the cover film is from 50
gr/inch to 500 gr/inch. [0796] 32. The film construction according
to any of the preceding embodiments directed to film construction
C, wherein the peel strength of the construction between the light
redirecting layer and the cover film is from 100 gr/inch to 500
gr/inch. [0797] 33. The film construction according to any of the
preceding embodiments directed to film construction C, wherein the
peel strength of the construction between the light redirecting
layer and the cover film is from 150 gr/inch to 500 gr/inch. [0798]
34. The film construction according to any of the preceding
embodiments directed to film construction C, wherein the peel
strength of the construction between the light redirecting layer
and the cover film is from 200 gr/inch to 500 gr/inch. [0799] 35.
The film construction according to any of the preceding embodiments
directed to film construction C, wherein the peel strength of the
construction between the light redirecting layer and the cover film
is from 250 gr/inch to 500 gr/inch. [0800] 36. The film
construction according to any of the preceding embodiments directed
to film construction C, wherein one or more of the microstructured
prismatic elements that have a first peak and a second peak, each
has a pitch, a height, and a valley angle, a first included angle
(alpha), and a second included angle (beta), wherein: [0801] the
pitch is 40.+-.3 microns; [0802] the height is 55.+-.3 microns;
[0803] the valley angle is 72.+-.2 degrees; [0804] the angle alpha
is 17.+-.2 degrees; and [0805] the angle beta is 10.+-.2 degrees.
[0806] 37. The film construction according to any of the preceding
embodiments directed to film construction C, wherein one or more of
the microstructured prismatic elements that have a first peak and a
second peak, each has a pitch, a height, and a valley angle, a
first included angle (alpha), and a second included angle (beta),
wherein: [0807] the pitch is 50.+-.3 microns; [0808] the height is
68.+-.3 microns; [0809] the valley angle is 72.+-.2 degrees; [0810]
the angle alpha is 17.+-.2 degrees; and [0811] the angle beta is
10.+-.2 degrees. [0812] 38. The film construction according to any
of the preceding embodiments directed to film construction C,
wherein one or more of the microstructured prismatic elements that
have a first peak and a second peak, each has a pitch, a height,
and a valley angle, a first included angle (alpha), and a second
included angle (beta), wherein: [0813] the pitch is from 35 to 55
microns; [0814] the height is from 45 to 78 microns; [0815] the
aspect ratio is from 1.2 to 1.5; [0816] the valley angle is from 60
to 80 degrees; [0817] the angle alpha is from 15 to 25 degrees; and
[0818] the angle beta is from 5 to 15 degrees. [0819] 39. The film
construction according to any of the preceding embodiments directed
to film construction C, wherein one or more of the microstructured
prismatic elements that have a first peak and a second peak, each
has a pitch, a height, and a valley angle, a first included angle
(alpha), and a second included angle (beta), wherein: [0820] the
pitch is from 35 to 55 microns; [0821] the height is from 40 to 72
microns; [0822] the aspect ratio is from 1.1 to 1.3; [0823] the
valley angle is from 50 to 70 degrees; [0824] the angle alpha is
from 18 to 28 degrees; and [0825] the angle beta is from 4 to 12
degrees. [0826] 40. The film construction according to any of the
preceding embodiments directed to film construction C, wherein one
or more of the microstructured prismatic elements that have a first
peak and a second peak, each has a pitch, a height, and a valley
angle, a first included angle (alpha), and a second included angle
(beta), wherein: [0827] the pitch is 40.+-.3 microns; [0828] the
height is 50.+-.3 microns; [0829] the valley angle is 60.+-.2
degrees; [0830] the angle alpha is 23.+-.2 degrees; and [0831] the
angle beta is 7.+-.2 degrees. [0832] 41. The film construction
according to any of the preceding embodiments directed to film
construction C, wherein one or more of the microstructured
prismatic elements that have a first peak and a second peak, each
has a pitch, a height, and a valley angle, a first included angle
(alpha), and a second included angle (beta), wherein: [0833] the
pitch is 50.+-.2 microns; [0834] the height is 61.+-.2 microns;
[0835] the valley angle is 60.+-.2 degrees; [0836] the angle alpha
is 23.+-.2 degrees; and [0837] the angle beta is 7.+-.2 degrees.
[0838] 42. The film construction according to any of the preceding
embodiments directed to film construction C, wherein one or more of
the microstructured prismatic elements that have a first peak and a
second peak, each has a pitch, a height, and a valley angle, a
first included angle (alpha), and a second included angle (beta),
wherein: [0839] the pitch is from 35 to 55 microns; [0840] the
height is from 45 to 78 microns; [0841] the aspect ratio is from
1.2 to 1.5; [0842] the valley angle is from 60 to 80 degrees;
[0843] the angle alpha is from 5 to 15 degrees; and [0844] the
angle beta is from 5 to 15 degrees. [0845] 43. The film
construction according to any of the preceding embodiments directed
to film construction C, wherein one or more of the microstructured
prismatic elements that have a first peak and a second peak, each
has a pitch, a height, and a valley angle, a first included angle
(alpha), and a second included angle (beta), wherein: [0846] the
pitch is 40.+-.2 microns; [0847] the height is 55.+-.2 microns;
[0848] the valley angle is 72.+-.2 degrees; [0849] the angle alpha
is 10
.+-.2 degrees; and [0850] the angle beta is 10.+-.2 degrees. [0851]
44. The film construction according to any of the preceding
embodiments directed to film construction C, wherein one or more of
the microstructured prismatic elements that have a first peak and a
second peak, each has a pitch, a height, and a valley angle, a
first included angle (alpha), and a second included angle (beta),
wherein: [0852] the pitch is 50.+-.2 microns; [0853] the height is
69.+-.2 microns; [0854] the valley angle is 72.+-.2 degrees; [0855]
the angle alpha is 10.+-.2 degrees; and [0856] the angle beta is
10.+-.2 degrees. [0857] 45. The film construction according to any
of the preceding embodiments directed to film construction C,
wherein one or more of the microstructured prismatic elements that
have a first peak and a second peak, each has a pitch, a height,
and a valley angle, a first included angle (alpha), and a second
included angle (beta), wherein: [0858] the pitch is from 35 to 55
microns; [0859] the height is from 45 to 78 microns; [0860] the
aspect ratio is from 1.2 to 1.4; [0861] the valley angle is from 60
to 80 degrees; [0862] the angle alpha is from 10 to 25 degrees; and
[0863] the angle beta is from 5 to 16 degrees. [0864] 46. The film
construction according to any of the preceding embodiments directed
to film construction C, wherein one or more of the microstructured
prismatic elements that have a first peak and a second peak, each
has a pitch, a height, and a valley angle, a first included angle
(alpha), and a second included angle (beta), wherein: [0865] the
pitch is 40.+-.2 microns; [0866] the height is 52.+-.2 microns;
[0867] the valley angle is 74.+-.2 degrees; [0868] the angle alpha
is 17.+-.2 degrees; and [0869] the angle beta is 12.+-.2 degrees.
[0870] 47. The film construction according to any of the preceding
embodiments directed to film construction C, wherein one or more of
the microstructured prismatic elements that have a first peak and a
second peak, each has a pitch, a height, and a valley angle, a
first included angle (alpha), and a second included angle (beta),
wherein: [0871] the pitch is 50.+-.2 microns; [0872] the height is
66.+-.2 microns; [0873] the valley angle is 74.+-.2 degrees; [0874]
the angle alpha is 17.+-.2 degrees; and [0875] the angle beta is
12.+-.2 degrees. [0876] 48. The film construction according to any
of the preceding embodiments directed to film construction C,
wherein H1>H2>H3>0 microns, and wherein H3 is less than 10
microns. [0877] 49. The film construction according to any of the
preceding embodiments directed to film construction C, wherein
H1>H2>H3>0 microns, and wherein H3 is less than 8 microns.
[0878] 50. The film construction according to any of the preceding
embodiments directed to film construction C, wherein
H1>H2>H3>0 microns, and wherein H3 is less than 6 microns.
[0879] 51. The film construction according to any of the preceding
embodiments directed to film construction C, wherein
H1>H2>H3>0 microns, and wherein H3 is less than 4 microns.
[0880] 52. The film construction according to any of the preceding
embodiments directed to film construction C, wherein the first peak
has an apex angle B1 and the second peak has an apex angle B2, and
wherein B1<B2. [0881] 53. The film construction according to any
of the preceding embodiments directed to film construction C,
wherein the light redirecting film comprises a light redirecting
substrate having first and second major surfaces, and wherein the
plurality of the microstructured prismatic elements are on the
second major surface of the light redirecting substrate. [0882] 54.
The film construction according to any of the preceding embodiments
directed to film construction C, wherein the light redirecting film
comprises a light redirecting substrate having first and second
major surfaces, and wherein the plurality of the microstructured
prismatic elements are on the second major surface of the light
redirecting substrate, and wherein the material of the light
redirecting substrate is different from the material of plurality
of microstructured prismatic elements. [0883] 55. The film
construction according to any of the preceding embodiments directed
to film construction C, wherein the light redirecting film
comprises a light redirecting substrate having first and second
major surfaces, and wherein the plurality of the microstructured
prismatic elements are on the second major surface of the light
redirecting substrate, and wherein the material of the light
redirecting substrate is the same as the material of plurality of
microstructured prismatic elements. [0884] 56. The film
construction according to any of the preceding embodiments directed
to film construction C, wherein the material of the plurality of
microstructured prismatic elements has refractive index from 1.25
to 1.65. [0885] 57. The film construction according to any of the
preceding embodiments directed to film construction C, wherein the
material of the plurality of microstructured prismatic elements has
refractive index from 1.35 to 1.65 [0886] 58. The film construction
according to any of the preceding embodiments directed to film
construction C, wherein the light redirecting film comprises a
light redirecting substrate having first and second major surfaces,
and wherein the plurality of the microstructured prismatic elements
are on the second major surface of the light redirecting substrate,
and wherein the light redirecting substrate diffuses visible light.
[0887] 59. The film construction according to any of the preceding
embodiments directed to film construction C, wherein the film
construction further comprises a diffuser chosen from bulk
diffusers, surface diffusers, embedded diffusers, and combinations
thereof [0888] 60. The film construction according to any of the
preceding embodiments directed to film construction C, wherein the
light redirecting film comprises a light redirecting substrate
having first and second major surfaces, and wherein the plurality
of the microstructured prismatic elements are on the second major
surface of the light redirecting substrate, and wherein the surface
roughness of the second major surface of the light redirecting
substrate diffuses visible light. [0889] 61. The film construction
according to any of the preceding embodiments directed to film
construction C, wherein the light redirecting film comprises a
light redirecting substrate having first and second major surfaces,
and wherein the plurality of the microstructured prismatic elements
are on the second major surface of the light redirecting substrate,
and wherein the surface roughness of the first major surface of the
light redirecting substrate diffuses visible light. [0890] 62. The
film construction according to any of the preceding embodiments
directed to film construction C, wherein the light redirecting film
comprises a light redirecting substrate having first and second
major surfaces, and wherein the plurality of the microstructured
prismatic elements are on the second major surface of the light
redirecting substrate, and wherein the film construction further
comprises a diffusing layer adjacent the first major surface of the
light redirecting substrate. [0891] 63. The film construction
according to any of the preceding embodiments directed to film
construction C, wherein the light redirecting film comprises a
light redirecting substrate having first and second major surfaces,
and wherein the plurality of the microstructured prismatic elements
are on the second major surface of the light redirecting substrate,
and wherein the film construction further comprises a diffusing
layer immediately adjacent the first major surface of the light
redirecting substrate. [0892] 64. The film construction according
to any of the preceding embodiments directed to film construction
C, wherein the film construction further comprises a diffusing
layer adjacent the second major surface of the cover film. [0893]
65. The film construction according to any of the preceding
embodiments directed to film construction C, wherein the film
construction further comprises a diffusing layer immediately
adjacent the second major surface of the cover film. [0894] 66. The
film construction according to any of the preceding embodiments
directed to film construction C, wherein the adhesive in the
adhesive layer is chosen from a pressure sensitive adhesive, a
thermoset adhesive, hot melt adhesive, a UV-curable adhesive, or a
combination thereof [0895] 67. The film construction according to
any of the preceding embodiments directed to film construction C,
wherein the adhesive in the adhesive layer is an UV-curable
pressure sensitive adhesive. [0896] 68. The film construction
according to any of the preceding embodiments directed to film
construction C, wherein the adhesive layer comprises one or more UV
stabilizers. [0897] 69. The film construction according to any of
the preceding embodiments directed to film construction C, wherein
the adhesive in the adhesive layer is an UV-curable pressure
sensitive adhesive, and wherein, after the adhesive has been
UV-cured, the adhesive does not creep. [0898] 70. The film
construction according to any of the preceding embodiments directed
to film construction C, wherein the adhesive in the adhesive layer
comprises a diffusing agent. [0899] 71. The film construction
according to any of the preceding embodiments directed to film
construction C, wherein the adhesive in the adhesive layer
comprises a diffusing agent and the diffusing agent is chosen from
micro beads and nanoparticles. [0900] 72. The film construction
according to any of the preceding embodiments directed to film
construction C, wherein the adhesive in the adhesive layer
comprises a diffusing agent and the diffusing agent is chosen from
micro beads having average size from 0.1 microns to 100 microns.
[0901] 73. The film construction according to any of the preceding
embodiments directed to film construction C, wherein the adhesive
in the adhesive layer comprises a diffusing agent and the diffusing
agent is chosen from micro beads having average size from 0.5
microns to 50 microns. [0902] 74. The film construction according
to any of the preceding embodiments directed to film construction
C, wherein the adhesive in the adhesive layer comprises a diffusing
agent and the diffusing agent is chosen from micro beads having
average size from 0.7 microns to 20 microns. [0903] 75. The film
construction according to any of the preceding embodiments directed
to film construction C, wherein the adhesive in the adhesive layer
comprises a diffusing agent and the diffusing agent is chosen from
micro beads having average size from 1 micron to 5 microns. [0904]
76. The film construction according to any of the preceding
embodiments directed to film construction C, wherein the adhesive
in the adhesive layer comprises a diffusing agent and the diffusing
agent is chosen from nanoparticles having average size from 1 nm to
100 nm. [0905] 77. The film construction according to any of the
preceding embodiments directed to film construction C, wherein the
adhesive in the adhesive layer comprises a diffusing agent and the
diffusing agent is chosen from nanoparticles having average size
from 5 nm to 50 nm. [0906] 78. The film construction according to
any of the preceding embodiments directed to film construction C,
wherein the adhesive in the adhesive layer comprises a diffusing
agent and the diffusing agent is chosen from nanoparticles having
average size from 5 nm to 30 nm. [0907] 79. The film construction
according to any of the preceding embodiments directed to film
construction C, wherein the adhesive in the adhesive layer
comprises a diffusing agent and the diffusing agent is chosen from
nanoparticles having average size from 1 nm to 20 nm. [0908] 80.
The film construction according to any of the preceding embodiments
directed to film construction C, wherein the thickness of the
adhesive layer is from 1 micron to 30 microns. [0909] 81. The film
construction according to any of the preceding embodiments directed
to film construction C, wherein the thickness of the adhesive layer
is from 1 micron to 20 microns. [0910] 82. The film construction
according to any of the preceding embodiments directed to film
construction C, wherein the thickness of the adhesive layer is from
1 micron to 10 microns. [0911] 83. The film construction according
to any of the preceding embodiments directed to film construction
C, wherein the thickness of the adhesive layer is from 1 micron to
5 microns. [0912] 84. The film construction according to any of the
preceding embodiments directed to film construction C, wherein the
thickness of the adhesive layer is from 2 micron to 10 microns.
[0913] 85. The film construction according to any of the preceding
embodiments directed to film construction C, wherein the first peak
of one or more of the microstructured prismatic elements penetrates
from 1 micron to 10 microns into the first major surface of the
adhesive layer. [0914] 86. The film construction according to any
of the preceding embodiments directed to film construction C,
wherein the first peak of one or more of the microstructured
prismatic elements penetrates from 1 micron to 8 microns into the
first major surface of the adhesive layer. [0915] 87. The film
construction according to any of the preceding embodiments directed
to film construction C, wherein the first peak of one or more of
the microstructured prismatic elements penetrates from 1 micron to
6 microns into the first major surface of the adhesive layer.
[0916] 88. The film construction according to any of the preceding
embodiments directed to film construction C, wherein the first peak
of one or more of the microstructured prismatic elements penetrates
from 1 micron to 5 microns into the first major surface of the
adhesive layer. [0917] 89. The film construction according to any
of the preceding embodiments directed to film construction C,
wherein the first peak of one or more of the microstructured
prismatic elements penetrates from 1 micron to 4 microns into the
first major surface of the adhesive layer. [0918] 90. The film
construction according to any of the preceding embodiments directed
to film construction C, wherein the one or more of the
microstructured prismatic elements have one or more curved facets.
[0919] 91. The film construction according to any of the preceding
embodiments directed to film construction C, wherein the film
construction has a visible light transmission from 10 to 100%.
[0920] 92. The film construction according to any of the preceding
embodiments directed to film construction C, wherein the film
construction has a visible light transmission from 20 to 100%.
[0921] 93. The film construction according to any of the preceding
embodiments directed to film construction C, wherein the film
construction has a visible light transmission from 20 to 95%.
[0922] 94. The film construction according to any of the preceding
embodiments directed to film construction C, wherein the film
construction has a visible light transmission from 20 to 85%.
[0923] 95. The film construction according to any of the preceding
embodiments directed to film construction C, wherein the film
construction has a visible light transmission from 30 to 80%.
[0924] 96. The film construction according to any of the preceding
embodiments directed to film construction C, wherein the cover film
is an optical film. [0925] 97. The film construction according to
any of the preceding embodiments directed to film construction C,
wherein the cover film is an infrared-reflecting film. [0926] 98.
The film construction according to any of the preceding embodiments
directed to film construction C, wherein the cover film diffuses
visible light. [0927] 99. The film construction according to any of
the preceding embodiments directed to film construction C, wherein
the cover film diffuses visible light by having a diffuser chosen
from bulk diffusers, surface diffusers, embedded diffusers, and
combinations thereof [0928] 100. The film construction according to
any of the preceding embodiments directed to film construction C,
wherein the second major surface of the cover film comprises a
coating. [0929] 101. The film construction according to any of the
preceding embodiments directed to film construction C, wherein the
second major surface of the cover film comprises a coating chosen
from hardcoats, anti-scratch coatings, low-surface energy coatings,
easy-clean coatings, anti-glare coatings, and combinations thereof.
[0930] 102. The film construction according to any of the preceding
embodiments directed to film construction C, wherein the film
construction has a rectangular or square shape and the edge of at
least one side is sealed with a sealing agent. [0931] 103. The film
construction according to any of the preceding embodiments directed
to film construction C, wherein the film construction has a
rectangular or square shape and the edge of at least one side is
sealed with an edge sealing tape. [0932] 104. The film construction
according to any of the preceding embodiments directed to film
construction C, wherein the film construction has a circular or
ellipsoidal shape and the edge of the film construction is sealed
all around. [0933] 105. The film construction according to any of
the preceding embodiments directed to film construction C, wherein
the film construction has a circular or ellipsoidal shape and at
least a portion of the edge of the film construction is sealed with
a sealing agent. [0934] 106. The film construction according to any
of the preceding embodiments directed to film construction C,
wherein the film construction has a circular or ellipsoidal shape
and at least a portion of the edge of the film construction is
sealed with an edge sealing tape. [0935] 107. The film construction
according to any of the preceding embodiments directed to film
construction C, wherein the light redirecting film comprises a
light redirecting substrate having first and second major surfaces,
and wherein the plurality of the microstructured prismatic elements
are on the second major surface of the light redirecting substrate,
and wherein the film construction further comprises a window film
adhesive layer adjacent the first major surface of the light
redirecting substrate. [0936] 108. The film construction according
to any of the preceding embodiments directed to film construction
C, wherein the film construction further comprises a window film
adhesive layer adjacent the second major surface of the cover film.
[0937] 109. The film construction according to any of the preceding
embodiments directed to film construction C, wherein the film
construction further comprises a window film adhesive layer, and
the window film adhesive layer comprises one or more UV
stabilizers. [0938] 110. A window film comprising a film
construction as claimed as in any of the preceding embodiments
directed to film construction C. [0939] 111. A glazing unit
comprising a film construction as claimed as in any of the
preceding embodiments directed to film construction C.
Exemplary Embodiments: Film Construction D
[0939] [0940] 1. A film construction D comprising: [0941] a light
redirecting film having a first major surface and a second major
surface opposite the first major surface, [0942] wherein the first
major surface of the light redirecting film comprises a plurality
of microstructured prismatic elements, [0943] wherein one or more
of the microstructured prismatic elements have three or more peaks,
[0944] wherein each of the peaks has a height, [0945] wherein the
first peak has a height larger than the height of each of the rest
of the peaks, [0946] wherein the difference between the height of
the first peak and the height of each of the rest of the peaks is,
independently from each other, from 2 microns to 10 microns, [0947]
an adhesive layer comprising an adhesive, wherein the adhesive
layer has a first major surface and a second major surface opposite
the first major surface, [0948] a cover film having a first major
surface and a second major surface opposite the first major
surface, wherein when the film construction is in a vertical
position, the first peak of the microstructured prismatic element
is positionally located above at least one of the rest of the
peaks, wherein each of the peaks has an apex angle, and wherein the
apex angle of the first peak is smaller than the apex angle of each
of the rest apex angles, wherein the first peak of one or more of
the microstructured prismatic elements penetrates at least
partially into the first major surface of the adhesive layer,
wherein the first major surface of the light redirecting film is
bonded to the first major surface of the adhesive layer, wherein
the second major surface of the adhesive layer is bonded to the
first major surface of the cover film. [0949] 2. The film
construction according to any of the preceding embodiments directed
to film construction D, wherein the first major surface of the
light redirecting film is bonded to the first major surface of the
adhesive layer, [0950] 3. The film construction according to any of
the preceding embodiments directed to film construction D, wherein
the second major surface of the adhesive layer is bonded to the
first major surface of the cover film [0951] 4. The film
construction according to any of the preceding embodiments directed
to film construction D, wherein H3 is from 2 microns to 8 microns.
[0952] 5. The film construction according to any of the preceding
embodiments directed to film construction D, wherein H3 is from 2
microns to 5 microns. [0953] 6. The film construction according to
any of the preceding embodiments directed to film construction D,
wherein the ratio H1/H2 is less than or equal to 5. [0954] 7. The
film construction according to any of the preceding embodiments
directed to film construction D, wherein the second major surface
of the adhesive layer is immediately adjacent to the first major
surface of the film. [0955] 8. The film construction according to
any of the preceding embodiments directed to film construction D,
wherein when the film construction is in a vertical position, the
first peak of the microstructured prismatic element is positionally
located above the second peak. [0956] 9. The film construction
according to any of the preceding embodiments directed to film
construction D, wherein at least 50% of the microstructured
prismatic elements have a first peak and a second peak. [0957] 10.
The film construction according to any of the preceding embodiments
directed to film construction D, wherein at least 75% of the
microstructured prismatic elements have a first peak and a second
peak. [0958] 11. The film construction according to any of the
preceding embodiments directed to film construction D, wherein at
least 90% of the microstructured prismatic elements have a first
peak and a second peak. [0959] 12. The film construction according
to any of the preceding embodiments directed to film construction
D, wherein at least 95% of the microstructured prismatic elements
have a first peak and a second peak. [0960] 13. The film
construction according to any of the preceding embodiments directed
to film construction D, wherein at least 98% of the microstructured
prismatic elements have a first peak and a second peak. [0961] 14.
The film construction according to any of the preceding embodiments
directed to film construction D, wherein at least 99% of the
microstructured prismatic elements have a first peak and a second
peak. [0962] 15. The film construction according to any of the
preceding embodiments directed to film construction D, wherein the
microstructured prismatic elements are arranged in contiguous rows
on the first major surface of the light redirecting film, and
wherein every other microstructured prismatic element within a row
has a first peak and a second peak. [0963] 16. The film
construction according to any of the preceding embodiments directed
to film construction D, wherein the microstructured prismatic
elements are arranged in contiguous rows on the first major surface
of the light redirecting film, and wherein every nth
microstructured prismatic element within a row has a first peak and
a second peak, wherein n is an integer from 3 to 25. [0964] 17. The
film construction according to any of the preceding embodiments
directed to film construction D, wherein the microstructured
prismatic elements are arranged in contiguous rows on the first
major surface of the light redirecting film, and wherein every nth
microstructured prismatic element within a row has a first peak and
a second peak, wherein n is 3. [0965] 18. The film construction
according to any of the preceding embodiments directed to film
construction D, wherein the microstructured prismatic elements are
arranged in contiguous rows on the first major surface of the light
redirecting film, and wherein every nth microstructured prismatic
element within a row has a first peak and a second peak, wherein n
is 5. [0966] 19. The film construction according to any of the
preceding embodiments directed to film construction D, wherein the
microstructured prismatic elements are arranged in contiguous rows
on the first major surface of the light redirecting film, and
wherein every nth microstructured prismatic element within a row
has a first peak and a second peak, wherein n is 10. [0967] 20. The
film construction according to any of the preceding embodiments
directed to film construction D, wherein the microstructured
prismatic elements are arranged in contiguous rows on the first
major surface of the light redirecting film, and wherein every nth
microstructured prismatic element within a row has a first peak and
a second peak, wherein n is 13. [0968] 21. The film construction
according to any of the preceding embodiments directed to film
construction D, wherein the microstructured prismatic elements are
arranged in contiguous rows on the first major surface of the light
redirecting film, and wherein every nth microstructured prismatic
element within a row has a first peak and a second peak, wherein n
is 15. [0969] 22. The film construction according to any of the
preceding embodiments directed to film construction D, wherein the
microstructured prismatic elements are arranged in contiguous rows
on the first major surface of the light redirecting film, and
wherein every nth microstructured prismatic element within a row
has a first peak and a second peak, wherein n is 20. [0970] 23. The
film construction according to any of the preceding embodiments
directed to film construction D, wherein the peel strength of the
construction between the light redirecting layer and the cover film
is 30 gr/inch or more. [0971] 24. The film construction according
to any of the preceding embodiments directed to film construction
D, wherein the peel strength of the construction between the light
redirecting layer and the cover film is from 30 gr/inch to 1000
gr/inch. [0972] 25. The film construction according to any of the
preceding embodiments directed to film construction D, wherein the
peel strength of the construction between the light redirecting
layer and the cover film is from 50 gr/inch to 1000 gr/inch. [0973]
26. The film construction according to any of the preceding
embodiments directed to film construction D, wherein the peel
strength of the construction between the light redirecting layer
and the cover film is from 100 gr/inch to 1000 gr/inch. [0974] 27.
The film construction according to any of the preceding embodiments
directed to film construction D, wherein the peel strength of the
construction between the light redirecting layer and the cover film
is from 30 gr/inch to 500 gr/inch. [0975] 28. The film construction
according to any of the preceding embodiments directed to film
construction D, wherein the peel strength of the construction
between the light redirecting layer and the cover film is from 50
gr/inch to 500 gr/inch. [0976] 29. The film construction according
to any of the preceding embodiments directed to film construction
D, wherein the peel strength of the construction between the light
redirecting layer and the cover film is from 100 gr/inch to 500
gr/inch. [0977] 30. The film construction according to any of the
preceding embodiments directed to film construction D, wherein the
peel strength of the construction between the light redirecting
layer and the cover film is from 150 gr/inch to 500 gr/inch. [0978]
31. The film construction according to any of the preceding
embodiments directed to film construction D, wherein the peel
strength of the construction between the light redirecting layer
and the cover film is from 200 gr/inch to 500 gr/inch. [0979] 32.
The film construction according to any of the preceding embodiments
directed to film construction D, wherein the peel strength of the
construction between the light redirecting layer and the cover film
is from 250 gr/inch to 500 gr/inch. [0980] 33. The film
construction according to any of the preceding embodiments directed
to film construction D, wherein one or more of the microstructured
prismatic elements that have a first peak and a second peak, each
has a pitch, a height, and a valley angle, a first included angle
(alpha), and a second included angle (beta), wherein: [0981] the
pitch is 40.+-.3 microns; [0982] the height is 55.+-.3 microns;
[0983] the valley angle is 72.+-.2 degrees; [0984] the angle alpha
is 17.+-.2 degrees; and [0985] the angle beta is 10.+-.2 degrees.
[0986] 34. The film construction according to any of the preceding
embodiments directed to film construction D, wherein one or more of
the microstructured prismatic elements that have a first peak and a
second peak, each has a pitch, a height, and a valley angle, a
first included angle (alpha), and a second included angle (beta),
wherein: [0987] the pitch is 50.+-.3 microns; [0988] the height is
68.+-.3 microns; [0989] the valley angle is 72.+-.2 degrees; [0990]
the angle alpha is 17.+-.2 degrees; and [0991] the angle beta is
10.+-.2 degrees. [0992] 35. The film construction according to any
of the preceding embodiments directed to film construction D,
wherein one or more of the microstructured prismatic elements that
have a first peak and a second peak, each has a pitch, a height,
and a valley angle, a first included angle (alpha), and a second
included angle (beta), wherein: [0993] the pitch is from 35 to 55
microns; [0994] the height is from 45 to 78 microns; [0995] the
aspect ratio is from 1.2 to 1.5; [0996] the valley angle is from 60
to 80 degrees; [0997] the angle alpha is from 15 to 25 degrees; and
[0998] the angle beta is from 5 to 15 degrees. [0999] 36. The film
construction according to any of the preceding embodiments directed
to film construction D, wherein one or more of the microstructured
prismatic elements that have a first peak and a second peak, each
has a pitch, a height, and a valley angle, a first included angle
(alpha), and a second included angle (beta), wherein: [1000] the
pitch is from 35 to 55 microns; [1001] the height is from 40 to 72
microns; [1002] the aspect ratio is from 1.1 to 1.3; [1003] the
valley angle is from 50 to 70 degrees; [1004] the angle alpha is
from 18 to 28 degrees; and [1005] the angle beta is from 4 to 12
degrees. [1006] 37. The film construction according to any of the
preceding embodiments directed to film construction D, wherein one
or more of the microstructured prismatic elements that have a first
peak and a second peak, each has a pitch, a height, and a valley
angle, a first included angle (alpha), and a second included angle
(beta), wherein: [1007] the pitch is 40.+-.3 microns; [1008] the
height is 50.+-.3 microns; [1009] the valley angle is 60.+-.2
degrees; [1010] the angle alpha is 23.+-.2 degrees; and [1011] the
angle beta is 7.+-.2 degrees. [1012] 38. The film construction
according to any of the preceding embodiments directed to film
construction D, wherein one or more of the microstructured
prismatic elements that have a first peak and a second peak, each
has a pitch, a height, and a valley angle, a first included angle
(alpha), and a second included angle (beta), wherein: [1013] the
pitch is 50.+-.2 microns; [1014] the height is 61.+-.2 microns;
[1015] the valley angle is 60.+-.2 degrees; [1016] the angle alpha
is 23.+-.2 degrees; and [1017] the angle beta is 7.+-.2 degrees.
[1018] 39. The film construction according to any of the preceding
embodiments directed to film construction D, wherein one or more of
the microstructured prismatic elements that have a first peak and a
second peak, each has a pitch, a height, and a valley angle, a
first included angle (alpha), and a second included angle (beta),
wherein: [1019] the pitch is from 35 to 55 microns; [1020] the
height is from 45 to 78 microns; [1021] the aspect ratio is from
1.2 to 1.5; [1022] the valley angle is from 60 to 80 degrees;
[1023] the angle alpha is from 5 to 15 degrees; and [1024] the
angle beta is from 5 to 15 degrees. [1025] 40. The film
construction according to any of the preceding embodiments directed
to film construction D, wherein one or more of the microstructured
prismatic elements that have a first peak and a second peak, each
has a pitch, a height, and a valley angle, a first included angle
(alpha), and a second included angle (beta), wherein: [1026] the
pitch is 40.+-.2 microns; [1027] the height is 55.+-.2 microns;
[1028] the valley angle is 72.+-.2 degrees; [1029] the angle alpha
is 10.+-.2 degrees; and [1030] the angle beta is 10.+-.2 degrees.
[1031] 41. The film construction according to any of the preceding
embodiments directed to film construction D, wherein one or more of
the microstructured prismatic elements that have a first peak and a
second peak, each has a pitch, a height, and a valley angle, a
first included angle (alpha), and a second included angle (beta),
wherein: [1032] the pitch is 50.+-.2 microns; [1033] the height is
69.+-.2 microns; [1034] the valley angle is 72.+-.2 degrees; [1035]
the angle alpha is 10
.+-.2 degrees; and [1036] the angle beta is 10.+-.2 degrees. [1037]
42. The film construction according to any of the preceding
embodiments directed to film construction D, wherein one or more of
the microstructured prismatic elements that have a first peak and a
second peak, each has a pitch, a height, and a valley angle, a
first included angle (alpha), and a second included angle (beta),
wherein: [1038] the pitch is from 35 to 55 microns; [1039] the
height is from 45 to 78 microns; [1040] the aspect ratio is from
1.2 to 1.4; [1041] the valley angle is from 60 to 80 degrees;
[1042] the angle alpha is from 10 to 25 degrees; and [1043] the
angle beta is from 5 to 16 degrees. [1044] 43. The film
construction according to any of the preceding embodiments directed
to film construction D, wherein one or more of the microstructured
prismatic elements that have a first peak and a second peak, each
has a pitch, a height, and a valley angle, a first included angle
(alpha), and a second included angle (beta), wherein: [1045] the
pitch is 40.+-.2 microns; [1046] the height is 52.+-.2 microns;
[1047] the valley angle is 74.+-.2 degrees; [1048] the angle alpha
is 17.+-.2 degrees; and [1049] the angle beta is 12.+-.2 degrees.
[1050] 44. The film construction according to any of the preceding
embodiments directed to film construction D, wherein one or more of
the microstructured prismatic elements that have a first peak and a
second peak, each has a pitch, a height, and a valley angle, a
first included angle (alpha), and a second included angle (beta),
wherein: [1051] the pitch is 50.+-.2 microns; [1052] the height is
66.+-.2 microns; [1053] the valley angle is 74.+-.2 degrees; [1054]
the angle alpha is 17.+-.2 degrees; and [1055] the angle beta is
12.+-.2 degrees. [1056] 45. The film construction according to any
of the preceding embodiments directed to film construction D,
wherein H1>H2>H3>0 microns, and wherein H3 is less than 10
microns. [1057] 46. The film construction according to any of the
preceding embodiments directed to film construction D, wherein
H1>H2>H3>0 microns, and wherein H3 is less than 8 microns.
[1058] 47. The film construction according to any of the preceding
embodiments directed to film construction D, wherein
H1>H2>H3>0 microns, and wherein H3 is less than 6 microns.
[1059] 48. The film construction according to any of the preceding
embodiments directed to film construction D, wherein
H1>H2>H3>0 microns, and wherein H3 is less than 4 microns.
[1060] 49. The film construction according to any of the preceding
embodiments directed to film construction D, wherein the first peak
has an apex angle B1 and the second peak has an apex angle B2, and
wherein B1<B2. [1061] 50. The film construction according to any
of the preceding embodiments directed to film construction D,
wherein the light redirecting film comprises a light redirecting
substrate having first and second major surfaces, and wherein the
plurality of the microstructured prismatic elements are on the
second major surface of the light redirecting substrate. [1062] 51.
The film construction according to any of the preceding embodiments
directed to film construction D, wherein the light redirecting film
comprises a light redirecting substrate having first and second
major surfaces, and wherein the plurality of the microstructured
prismatic elements are on the second major surface of the light
redirecting substrate, and wherein the material of the light
redirecting substrate is different from the material of plurality
of microstructured prismatic elements. [1063] 52. The film
construction according to any of the preceding embodiments directed
to film construction D, wherein the light redirecting film
comprises a light redirecting substrate having first and second
major surfaces, and wherein the plurality of the microstructured
prismatic elements are on the second major surface of the light
redirecting substrate, and wherein the material of the light
redirecting substrate is the same as the material of plurality of
microstructured prismatic elements. [1064] 53. The film
construction according to any of the preceding embodiments directed
to film construction D, wherein the material of the plurality of
microstructured prismatic elements has refractive index from 1.25
to 1.65. [1065] 54. The film construction according to any of the
preceding embodiments directed to film construction D, wherein the
material of the plurality of microstructured prismatic elements has
refractive index from 1.35 to 1.65 [1066] 55. The film construction
according to any of the preceding embodiments directed to film
construction D, wherein the light redirecting film comprises a
light redirecting substrate having first and second major surfaces,
and wherein the plurality of the microstructured prismatic elements
are on the second major surface of the light redirecting substrate,
and wherein the light redirecting substrate diffuses visible light.
[1067] 56. The film construction according to any of the preceding
embodiments directed to film construction D, wherein the film
construction further comprises a diffuser chosen from bulk
diffusers, surface diffusers, embedded diffusers, and combinations
thereof [1068] 57. The film construction according to any of the
preceding embodiments directed to film construction D, wherein the
light redirecting film comprises a light redirecting substrate
having first and second major surfaces, and wherein the plurality
of the microstructured prismatic elements are on the second major
surface of the light redirecting substrate, and wherein the surface
roughness of the second major surface of the light redirecting
substrate diffuses visible light. [1069] 58. The film construction
according to any of the preceding embodiments directed to film
construction D, wherein the light redirecting film comprises a
light redirecting substrate having first and second major surfaces,
and wherein the plurality of the microstructured prismatic elements
are on the second major surface of the light redirecting substrate,
and wherein the surface roughness of the first major surface of the
light redirecting substrate diffuses visible light. [1070] 59. The
film construction according to any of the preceding embodiments
directed to film construction D, wherein the light redirecting film
comprises a light redirecting substrate having first and second
major surfaces, and wherein the plurality of the microstructured
prismatic elements are on the second major surface of the light
redirecting substrate, and wherein the film construction further
comprises a diffusing layer adjacent the first major surface of the
light redirecting substrate. [1071] 60. The film construction
according to any of the preceding embodiments directed to film
construction D, wherein the light redirecting film comprises a
light redirecting substrate having first and second major surfaces,
and wherein the plurality of the microstructured prismatic elements
are on the second major surface of the light redirecting substrate,
and wherein the film construction further comprises a diffusing
layer immediately adjacent the first major surface of the light
redirecting substrate. [1072] 61. The film construction according
to any of the preceding embodiments directed to film construction
D, wherein the film construction further comprises a diffusing
layer adjacent the second major surface of the cover film. [1073]
62. The film construction according to any of the preceding
embodiments directed to film construction D, wherein the film
construction further comprises a diffusing layer immediately
adjacent the second major surface of the cover film. [1074] 63. The
film construction according to any of the preceding embodiments
directed to film construction D, wherein the adhesive in the
adhesive layer is chosen from a pressure sensitive adhesive, a
thermoset adhesive, hot melt adhesive, a UV-curable adhesive, or a
combination thereof. [1075] 64. The film construction according to
any of the preceding embodiments directed to film construction D,
wherein the adhesive in the adhesive layer is an UV-curable
pressure sensitive adhesive. [1076] 65. The film construction
according to any of the preceding embodiments directed to film
construction D, wherein the adhesive layer comprises one or more UV
stabilizers. [1077] 66. The film construction according to any of
the preceding embodiments directed to film construction D, wherein
the adhesive in the adhesive layer is an UV-curable pressure
sensitive adhesive, and wherein, after the adhesive has been
UV-cured, the adhesive does not creep. [1078] 67. The film
construction according to any of the preceding embodiments directed
to film construction D, wherein the adhesive in the adhesive layer
comprises a diffusing agent. [1079] 68. The film construction
according to any of the preceding embodiments directed to film
construction D, wherein the adhesive in the adhesive layer
comprises a diffusing agent and the diffusing agent is chosen from
micro beads and nanoparticles. [1080] 69. The film construction
according to any of the preceding embodiments directed to film
construction D, wherein the adhesive in the adhesive layer
comprises a diffusing agent and the diffusing agent is chosen from
micro beads having average size from 0.1 microns to 100 microns.
[1081] 70. The film construction according to any of the preceding
embodiments directed to film construction D, wherein the adhesive
in the adhesive layer comprises a diffusing agent and the diffusing
agent is chosen from micro beads having average size from 0.5
microns to 50 microns. [1082] 71. The film construction according
to any of the preceding embodiments directed to film construction
D, wherein the adhesive in the adhesive layer comprises a diffusing
agent and the diffusing agent is chosen from micro beads having
average size from 0.7 microns to 20 microns. [1083] 72. The film
construction according to any of the preceding embodiments directed
to film construction D, wherein the adhesive in the adhesive layer
comprises a diffusing agent and the diffusing agent is chosen from
micro beads having average size from 1 micron to 5 microns. [1084]
73. The film construction according to any of the preceding
embodiments directed to film construction D, wherein the adhesive
in the adhesive layer comprises a diffusing agent and the diffusing
agent is chosen from nanoparticles having average size from 1 nm to
100 nm. [1085] 74. The film construction according to any of the
preceding embodiments directed to film construction D, wherein the
adhesive in the adhesive layer comprises a diffusing agent and the
diffusing agent is chosen from nanoparticles having average size
from 5 nm to 50 nm. [1086] 75. The film construction according to
any of the preceding embodiments directed to film construction D,
wherein the adhesive in the adhesive layer comprises a diffusing
agent and the diffusing agent is chosen from nanoparticles having
average size from 5 nm to 30 nm. [1087] 76. The film construction
according to any of the preceding embodiments directed to film
construction D, wherein the adhesive in the adhesive layer
comprises a diffusing agent and the diffusing agent is chosen from
nanoparticles having average size from 1 nm to 20 nm. [1088] 77.
The film construction according to any of the preceding embodiments
directed to film construction D, wherein the thickness of the
adhesive layer is from 1 micron to 30 microns. [1089] 78. The film
construction according to any of the preceding embodiments directed
to film construction D, wherein the thickness of the adhesive layer
is from 1 micron to 20 microns. [1090] 79. The film construction
according to any of the preceding embodiments directed to film
construction D, wherein the thickness of the adhesive layer is from
1 micron to 10 microns. [1091] 80. The film construction according
to any of the preceding embodiments directed to film construction
D, wherein the thickness of the adhesive layer is from 1 micron to
5 microns. [1092] 81. The film construction according to any of the
preceding embodiments directed to film construction D, wherein the
thickness of the adhesive layer is from 2 micron to 10 microns.
[1093] 82. The film construction according to any of the preceding
embodiments directed to film construction D, wherein the first peak
of one or more of the microstructured prismatic elements penetrates
from 1 micron to 10 microns into the first major surface of the
adhesive layer. [1094] 83. The film construction according to any
of the preceding embodiments directed to film construction D,
wherein the first peak of one or more of the microstructured
prismatic elements penetrates from 1 micron to 8 microns into the
first major surface of the adhesive layer. [1095] 84. The film
construction according to any of the preceding embodiments directed
to film construction D, wherein the first peak of one or more of
the microstructured prismatic elements penetrates from 1 micron to
6 microns into the first major surface of the adhesive layer.
[1096] 85. The film construction according to any of the preceding
embodiments directed to film construction D, wherein the first peak
of one or more of the microstructured prismatic elements penetrates
from 1 micron to 5 microns into the first major surface of the
adhesive layer. [1097] 86. The film construction according to any
of the preceding embodiments directed to film construction D,
wherein the first peak of one or more of the microstructured
prismatic elements penetrates from 1 micron to 4 microns into the
first major surface of the adhesive layer. [1098] 87. The film
construction according to any of the preceding embodiments directed
to film construction D, wherein the one or more of the
microstructured prismatic elements have one or more curved facets.
[1099] 88. The film construction according to any of the preceding
embodiments directed to film construction D, wherein the film
construction has a visible light transmission from 10 to 100%.
[1100] 89. The film construction according to any of the preceding
embodiments directed to film construction D, wherein the film
construction has a visible light transmission from 20 to 100%.
[1101] 90. The film construction according to any of the preceding
embodiments directed to film construction D, wherein the film
construction has a visible light transmission from 20 to 95%.
[1102] 91. The film construction according to any of the preceding
embodiments directed to film construction D, wherein the film
construction has a visible light transmission from 20 to 85%.
[1103] 92. The film construction according to any of the preceding
embodiments directed to film construction D, wherein the film
construction has a visible light transmission from 30 to 80%.
[1104] 93. The film construction according to any of the preceding
embodiments directed to film construction D, wherein the cover film
is an optical film.
[1105] 94. The film construction according to any of the preceding
embodiments directed to film construction D, wherein the cover film
is an infrared-reflecting film. [1106] 95. The film construction
according to any of the preceding embodiments directed to film
construction D, wherein the cover film diffuses visible light.
[1107] 96. The film construction according to any of the preceding
embodiments directed to film construction D, wherein the cover film
diffuses visible light by having a diffuser chosen from bulk
diffusers, surface diffusers, embedded diffusers, and combinations
thereof. [1108] 97. The film construction according to any of the
preceding embodiments directed to film construction D, wherein the
second major surface of the cover film comprises a coating. [1109]
98. The film construction according to any of the preceding
embodiments directed to film construction D, wherein the second
major surface of the cover film comprises a coating chosen from
hardcoats, anti-scratch coatings, low-surface energy coatings,
easy-clean coatings, anti-glare coatings, and combinations thereof.
[1110] 99. The film construction according to any of the preceding
embodiments directed to film construction D, wherein the film
construction has a rectangular or square shape and the edge of at
least one side is sealed with a sealing agent. [1111] 100. The film
construction according to any of the preceding embodiments directed
to film construction D, wherein the film construction has a
rectangular or square shape and the edge of at least one side is
sealed with an edge sealing tape. [1112] 101. The film construction
according to any of the preceding embodiments directed to film
construction D, wherein the film construction has a circular or
ellipsoidal shape and the edge of the film construction is sealed
all around. [1113] 102. The film construction according to any of
the preceding embodiments directed to film construction D, wherein
the film construction has a circular or ellipsoidal shape and at
least a portion of the edge of the film construction is sealed with
a sealing agent. [1114] 103. The film construction according to any
of the preceding embodiments directed to film construction D,
wherein the film construction has a circular or ellipsoidal shape
and at least a portion of the edge of the film construction is
sealed with an edge sealing tape. [1115] 104. The film construction
according to any of the preceding embodiments directed to film
construction D, wherein the light redirecting film comprises a
light redirecting substrate having first and second major surfaces,
and wherein the plurality of the microstructured prismatic elements
are on the second major surface of the light redirecting substrate,
and wherein the film construction further comprises a window film
adhesive layer adjacent the first major surface of the light
redirecting substrate. [1116] 105. The film construction according
to any of the preceding embodiments directed to film construction
D, wherein the film construction further comprises a window film
adhesive layer adjacent the second major surface of the cover film.
[1117] 106. The film construction according to any of the preceding
embodiments directed to film construction D, wherein the film
construction further comprises a window film adhesive layer, and
the window film adhesive layer comprises one or more UV
stabilizers. [1118] 107. A window film comprising a film
construction as claimed as in any of the preceding embodiments
directed to film construction D. [1119] 108. A glazing unit
comprising a film construction as claimed as in any of the
preceding embodiments directed to film construction D.
* * * * *